Carrier 17EX User Manual

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Page 1

17EX

Externally Geared Centrifugal Liquid Chillers

50/60 Hz

1500 to 2250 Nominal Tons (5280 to 7910 kW)

Start-Up,Operation,andMaintenanceInstructions

SAFETY CONSIDERATIONS

Centrifugal liquid chillers are designed to provide safe and reliable service when operated within design speciﬁcations. When operating this equipment, use good judgment and safety precautions to avoid damage to equipment and property or injury to personnel.

Be sure you understand and follow the procedures and safety precautions contained in the chiller instructions as well as those listed in this guide.

DO NOT VENT refrigerant relief valves within a building. Outlet from rupture disc or relief valve must be vented outdoors in accordance with the latest edition of ASHRAE (American Society of Heating, Refrigeration, and Air Conditioning Engineers) 15. The accumulation of refrigerant in an enclosed space can displace oxygen and cause asphyxiation.

PROVIDE adequate ventilation in accordance with ASHRAE 15, especially for enclosed and low overhead spaces. Inhalation of high concentrations of vapor is harmful and may cause heart irregularities, unconsciousness, or death. Misuse can be fatal.Vaporisheavier than air and reduces the amount of oxygen available for breathing. Product causes eye and skin irritation. Decomposition products are hazardous.

DO NOT USE OXYGEN to purge lines or to pressurize a chiller for any purpose. Oxygen gas reacts violently with oil, grease, and other common substances.

NEVER EXCEED speciﬁed test pressures, VERIFY the allowable test pressure by checking the instruction literature and the design pressures on the equipment nameplate.

DO NOT USE air for leak testing. Use only refrigerant or dry nitrogen.

DO NOT VALVE OFF any safety device. BE SURE that all pressure relief devices are properly installed and

functioning before operating any machine.

DO NOT WELD OR FLAME CUT any refrigerant line or vessel until all refrigerant (liquid andvapor)hasbeenremovedfromchiller. Traces of vapor should be displaced with dry air or nitrogen and the work area should be well ventilated. Refrigerant in contact with

an open ﬂame produces toxic gases.

DO NOT USE eyebolts or eyebolt holes to rig chiller sections or the entire assembly.

DO NOT work on high-voltage equipment unless you are a qualiﬁed electrician.

DO NOTWORKON electrical components, including control panels, switches, starters, or oil heater until you are sure ALLPOWER IS OFF and no residual voltage can leak from capacitors or solidstate components.

LOCK OPENANDTAGelectrical circuits during servicing.IF WORK IS INTERRUPTED, conﬁrm that all circuits are deenergized before resuming work.

AVOID SPILLING liquid refrigerant on skin or getting it into the eyes. USE SAFETY GOGGLES. Wash any spills from the skin with soap and water .If any enters the eyes, IMMEDIATELYFLUSH EYES with water and consult a physician.

NEVER APPLY an open ﬂame or live steam to a refrigerant cylinder. Dangerous overpressure can result. When necessary to heat refrigerant, use only warm (110 F [43 C]) water.

DO NOT REUSE disposable (nonreturnable) cylinders or attempt to reﬁll them. It is DANGEROUS AND ILLEGAL. When cylinder is emptied, evacuate remaining gas pressure, loosen the collar and unscrew and discard the valve stem. DO NOT INCINERATE.

CHECK THE REFRIGERANT TYPE before adding refrigerant to the chiller.The introduction of the wrong refrigerant can cause damage or malfunction to this chiller.

Operation of this equipment with refrigerants other than those cited herein should comply withASHRAE-15 (latest edition). Contact Carrier for further information on use of this chiller with other refrigerants.

DO NOTATTEMPTTO REMOVE ﬁttings, covers,etc., while chiller is under pressure or while chiller is running. Be sure pressure is at 0 psig (0 kPa) before breaking any refrigerant connection.

CAREFULLY INSPECT all relief devices, rupture discs, and other relief devices AT LEAST ONCE A YEAR. If chiller operates in a corrosive atmosphere, inspect the devices at more frequent intervals.

DO NOT ATTEMPT TO REPAIR OR RECONDITION any relief device when corrosion or build-up of foreign material (rust, dirt, scale, etc.) is found within the valve body or mechanism. Replace the device.

DO NOT install relief devices in series or backwards. USE CARE when working near or in line with a compressed spring.

Sudden release of the spring can cause it and objects in its path to act as projectiles.

RUN WATERPUMPS when removing, transferring, or charging refrigerant.

DO NOT STEP on refrigerant lines. Broken lines can whip about and cause personal injury.

DO NOT climb over a chiller. Use platform, catwalk, or staging. Follow safe practices when using ladders.

USE MECHANICAL EQUIPMENT (crane, hoist, etc.) to lift or move inspection covers or other heavy components. Even if components are light, use such equipment when there is a risk of slipping or losing your balance.

BE AWARE that certain automatic start arrangements CAN ENGAGE THE STARTER. Open the disconnect ahead of the starter in addition to shutting off the machine or pump.

USE only repair or replacement parts that meet the code requirements of the original equipment.

DO NOTVENT OR DRAIN waterboxes containingindustrial brines, liquid, gases, or semisolids without permission of your process control group.

DO NOT LOOSEN waterbox cover bolts until the waterbox has been completely drained.

DOUBLE-CHECK that coupling nut wrenches, dial indicators, or other items have been removed before rotating any shafts.

DO NOT LOOSEN a packing gland nut before checking that the nut has a positive thread engagement.

PERIODICALLY INSPECT all valves, ﬁttings, and piping for corrosion, rust, leaks, or damage.

PROVIDE A DRAIN connection in the vent line near each pressure relief device to prevent a build-up of condensate or rain water.

Manufacturer reserves the right to discontinue, or change at any time, speciﬁcations or designs without notice and without incurring obligations.

Book 2 Tab 5d

PC 211 Catalog No. 531-721 Printed in U.S.A. Form 17EX-1SS Pg 1 7-97 Replaces: New

Page 2

CONTENTS

Page

SAFETY CONSIDERATIONS ......................1

INTRODUCTION ABBREVIATIONS 17EX CHILLER FAMILIARIZATION

Chiller Identiﬁcation Label System Components Cooler Condenser Compressor Control Center Motor Starter (Purchased Separately) Economizer/Storage Vessel

REFRIGERATION CYCLE OIL COOLING CYCLE

Compressor Oil Cooling External Gear Oil Cooling LUBRICATION CYCLE Compressor Lubrication Cycle External Gear Lubrication Cycle

STARTERS CONTROLS

Deﬁnitions

........................................5

................................5

...............................5

.................5

.......................5

............................5

....................................5

...................................5

.................................5

..............5

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.......................5-8

...........................8

.........................8

........................8

..........................8,9

...................8

..................9

....................................9

.................................11-43

....................................11

• ANALOG SIGNAL

• DIGITAL SIGNAL

• VOLATILE MEMORY

General PIC System Components

......................................11

.......................12

• PROCESSOR/SENSOR INPUT/OUTPUT MODULE (PSIO)

• STARTER MANAGEMENT MODULE (SMM)

• LOCAL INTERFACE DEVICE (LID)

• SIX-PACK RELAY BOARD

• EIGHT-INPUT MODULES

• FOUR-IN/TWO-OUT (4-IN/2-OUT) MODULE

• OIL HEATER CONTACTOR (1C)

• COMPRESSOR OIL PUMP CONTACTOR (2C) AND GEAR

OIL PUMP CONTACTOR (5C)

• HOT GAS BYPASS CONTACTOR RELAY (3C) (Optional)

• OIL AUXILIARY RELAY (4C)

• CONTROL TRANSFORMERS (T1-T4)

• CONTROL AND OIL HEATER VOLTAGE

SELECTOR (S1)

• OIL DIFFERENTIAL PRESSURE/POWER SUPPLY

MODULE

LID Operation and Menus

.......................16

• GENERAL

• ALARMS AND ALERTS

• LID DEFAULT SCREEN MENU ITEMS

• MENU STRUCTURE

• TO VIEW OR CHANGE POINT STATUS

• OVERRIDE OPERATIONS

• TO VIEW OR CHANGE TIME SCHEDULE OPERATION

• TO VIEW AND CHANGE SET POINTS

• SERVICE OPERATION

PIC System Functions

..........................32

• CAPACITY CONTROL

• ENTERING CHILLED WATER CONTROL

• DEADBAND

• PROPORTIONAL BANDS AND GAIN

• DEMAND LIMITING

• CHILLER TIMERS

• OCCUPANCY SCHEDULE

Safety Controls

...............................33

• SHUNT TRIP

Default Screen Freeze .........................33

Auxiliary Compressor Oil Pump Control Auxiliary Gear Oil Pump Control Shaft Seal Oil Control Ramp Loading Control Capacity Override High Discharge Temperature Control Oil Sump Temperature Control Oil Cooler Remote Start/Stop Controls Spare Safety Inputs Spare Alarm Contacts Condenser Pump Control Condenser Freeze Prevention Tower-Fan Relay Auto. Restart After Power Failure Water/Brine Reset Demand Limit Control, Option (Requires Optional

8-Input Module) Surge Prevention Algorithm Surge Protection Lead/Lag Control

....................................36

..........................33

.........................33

.............................35

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..........33

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.............35

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• COMMON POINT SENSOR INSTALLATION

• CHILLER COMMUNICATION WIRING

• LEAD/LAG OPERATION

• FAULTED CHILLER OPERATION

• LOAD BALANCING

• AUTO. RESTART AFTER POWER FAILURE

Ice Build Control

..............................40

• ICE BUILD INITIATION

• START-UP/RECYCLE OPERATION

• TEMPERATURE CONTROL DURING ICE BUILD

• TERMINATION OF ICE BUILD

• RETURN TO NON-ICE BUILD OPERATIONS

Attach to Network Device Control

...............41

• ATTACHING TO OTHER CCN MODULES

Service Operation

.............................42

• TO ACCESS THE SERVICE SCREENS

• TO LOG OFF

• HOLIDAY SCHEDULING

START-UP/SHUTDOWN/RECYCLE SEQUENCE Local Start-Up Shutdown Sequence Automatic Soft Stop Amps Threshold Chilled Water Recycle Mode Safety Shutdown

BEFORE INITIAL START-UP Job Data Required Equipment Required Using the Economizer/Storage Vessel and Pumpout

System Remove Shipping Packaging

................................43

...........................44

............44

....................44

..............................45

...................45-57

............................45

...........................45

....................................45

...................45

...43-45

• MOTOR

• EXTERNAL GEAR

Motor Electrical Connection Motor Auxiliary Devices Open Oil Circuit Valves Tighten All Gasketed Joints and Guide Vane

Shaft Packing Check Chiller Tightness Refrigerant Tracer Leak Test the Chiller Standing Vacuum Test Chiller Dehydration

...............................46

.............................46

...........................46

............................49

....................45

........................46

.........................49

Page 3

CONTENTS

Page

Inspect Water Piping ..........................50

Check Optional Pumpout Compressor Water

Piping Check Relief Devices Inspect Wiring

....................................50

..........................50

................................50

• CHECK INSULATION RESISTANCE

Motor Pre-Start Checks External Gear Pre-Start Checks Carrier Comfort Network Interface Check Starter

.................................53

........................51

.................51

...............53

• MECHANICAL STARTERS

• SOLID-STATE STARTERS

Compressor Oil Charge Power Up the Controls and

Check the Compressor Oil Heater

........................54

.............54

• SOFTWARE VERSION

Set Up Chiller Control Conﬁguration Input the Design Set Points Input the Local Occupied Schedule

(OCCPC01S)

Input Service Conﬁgurations

................................54

.....................54

....................54

.............54

• PASSWORD

• INPUT TIME AND DATE

• CHANGE LID CONFIGURATION IF NECESSARY

• MODIFY CONTROLLER IDENTIFICATION IF

NECESSARY

• INPUT EQUIPMENT SERVICE PARAMETERS IF

NECESSARY

• MODIFY EQUIPMENT CONFIGURATION IF

NECESSARY

• CHECK VOLTAGE SUPPLY

• PERFORM AN AUTOMATED CONTROL TEST

Check Pumpout System Controls and Optional

Pumpout Compressor High Altitude Locations Charge Refrigerant Into Chiller

........................56

........................57

..................57

• TRIMMING REFRIGERANT CHARGE

INITIAL START-UP Preparation Manual Operation of the Guide Vanes Dry Run to Test Start-Up Sequence Check Motor Rotation

...........................57-62

..................................57

............58

..............58

.........................58

• INITIAL MOTOR START-UP

Disc Coupling Installation and Alignment

.........59

• IMPORTANT INFORMATION

Check Oil Pressure and Compressor Stop Calibrate Motor Current Demand Setting To Prevent Accidental Start-Up Hot Alignment Check Doweling Check Chiller Operating Condition Instruct the Operator

....................................61

.........................61

..........................62

..................61

...............61

........61

..........61

• COOLER-CONDENSER

• ECONOMIZER/STORAGE VESSEL

• PUMPOUT SYSTEM

• COMPRESSOR ASSEMBLY

• COMPRESSOR LUBRICATION SYSTEM

EXTERNAL GEAR LUBRICATION SYSTEM

• CONTROL SYSTEM

• AUXILIARY EQUIPMENT

• CHILLER CYCLES

• MAINTENANCE

• SAFETY DEVICES AND PROCEDURES

• CHECK OPERATOR KNOWLEDGE

• THIS MANUAL

OPERATING INSTRUCTIONS Operator Duties

...............................62

..................62,63

Prepare the Chiller for Start-Up .................62

Starting the Chiller Check the Running System Stopping the Chiller After Limited Shutdown Extended Shutdown After Extended Shutdown Cold Weather Operation Manual Guide Vane Operation Refrigeration Log

PUMPOUT AND REFRIGERANT TRANSFER

PROCEDURES Preparation Operating the Optional Pumpout

Compressor

..................................63

........................... 62

.....................62

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............................63-67

................................63

• READING REFRIGERANT PRESSURES

Transferring Refrigerant into the

Economizer/Storage Vessel Transferring Refrigerant into

the Cooler/Condenser/Compressor Section Return Chiller to Normal Operating

Conditions GENERAL MAINTENANCE

Refrigerant Properties Adding Refrigerant Removing Refrigerant Adjusting the Refrigerant Charge Refrigerant Leak Testing Leak Rate Test After Service, Repair, or Major Leak

.................................67

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...................66

.....67

....................67-75

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.......................67

.........67

• REFRIGERANT TRACER

• TO PRESSURIZE WITH DRY NITROGEN

Repair the Leak, Retest, and Apply

Standing Vacuum Test Checking Guide Vane Linkage Contact Seal Maintenance

.......................68

..................68

......................68

• SEAL DISASSEMBLY

• SEAL REASSEMBLY

Chiller Alignment

.............................71

• ALIGNMENT METHODS

• PRELIMINARY ALIGNMENT

• NEAR FINAL ALIGNMENT

• FINAL ALIGNMENT

• HOT ALIGNMENT CHECK

• DOWELING

WEEKLY MAINTENANCE Check the Lubrication System

SCHEDULED MAINTENANCE Service Ontime Inspect the Control Center Check Safety and Operating Controls Monthly Changing the Oil Filters

...............................76

.......................76

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..................76-83

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.....76

........................76

• COMPRESSOR OIL FILTER

• EXTERNAL GEAR OIL FILTER

Oil Speciﬁcations Oil Changes

.............................77

..................................77

• COMPRESSOR OIL

• EXTERNAL GEAR OIL

• MOTOR SLEEVE BEARING AND PUMPOUT

COMPRESSOR OIL

Inspect Refrigerant Float System Inspect Relief Valves and Piping Coupling Maintenance Motor Maintenance

........................78

............................78

................78

• CLEANLINESS

• SLEEVE BEARINGS

Page 4

CONTENTS (cont)

Page

Motor Handling/Rigging ........................81

Motor Storage External Gear Storage

................................81

.........................81

• SHORT-TERM STORAGE (Indoors)

• LONG-TERM STORAGE (Indoors)

• EXTENDED DOWNTIME

Compressor Bearing Maintenance External Gear Maintenance Inspect the Heat Exchanger Tubes

...............82

.....................82

...............82

• COOLER

• CONDENSER

Water Leaks Water Treatment Inspect the Starting Equipment Check Pressure Transducers Pumpout System Maintenance

..................................82

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.................83

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..................83

• OPTIONAL PUMPOUT COMPRESSOR OIL CHARGE

• PUMPOUT SAFETY CONTROL SETTINGS

Ordering Replacement Chiller Parts

..............83

• MOTOR REPLACEMENT PARTS

• EXTERNAL GEAR REPLACEMENT PARTS

TROUBLESHOOTING GUIDE Overview Checking the Display Messages Checking Temperature Sensors

....................................83

..................83-99

.................84

• RESISTANCE CHECK

• VOLTAGE DROP

• CHECK SENSOR ACCURACY

• DUAL TEMPERATURE SENSORS

Checking Pressure Transducers ................84

• OIL DIFFERENTIAL PRESSURE/POWER SUPPLY

MODULE CALIBRATION

• TROUBLESHOOTING TRANSDUCERS

• TRANSDUCER REPLACEMENT

Control Algorithms Checkout Procedure Control Test Control Modules

.................................85

..............................96

.........85

• RED LEDs

• GREEN LEDs

Notes on Module Operation Processor/Sensor Input/Output Module (PSIO)

....................96

....97

• INPUTS

• OUTPUTS

Starter Management Module (SMM)

..............97

• INPUTS

• OUTPUTS

Options Modules (8-Input) Four-In/Two-Out Module

.....................98

.......................98

• INPUTS

• OUTPUTS

Replacing Defective Processor Modules

.........98

• INSTALLATION OF NEW PSIO MODULE

PHYSICAL DATA AND WIRING SCHEMATICS INDEX

INITIAL START-UP CHECKLIST FOR 17EX

....................................115-120

EXTERNALLY GEARED CENTRIFUGAL LIQUID CHILLER

..........................CL-1 to CL-12

....99-114

Page 5

INTRODUCTION

Before initial start-up of the 17EX unit, those involved in the start-up, operation, and maintenance should be thoroughly familiar with these instructions and other necessary job data. This book is outlined so that you may become familiar with the control system before performing start-up procedures. Procedures in this manual are arranged in the sequence required for proper chiller start-up and operation.

This unit uses a microprocessor controlled system. Do not short or jumper between terminations on circuit boards or modules; control or board failure may result.

Be aware of electrostatic discharge (static electricity) when handling or making contact with circuit boards or module connections. Always touch a chassis (grounded) part to dissipate body electrostatic charge before working inside the control center.

Use extreme care when handling tools near boards and when connecting or disconnecting terminal plugs. Circuit boards can easily be damaged. Always hold boards by the edges and avoid touching components and connections.

This equipment uses, and can radiate, radio frequency energy. If not installed and used in accordance with the instruction manual, it may cause interference to radio communications. It has been tested and found to comply with the limits for a Class A computing device pursuant to Subpart J of Part 15 of FCC Rules, which are designed to provide reasonable protection against such interference when operated in a commercial environment. Operation of this equipment in a residential area is likely to cause interference, in which case the user, at his own expense, will be required to take whatever measures may be required to correct the interference.

Always store and transport replacement or defective boards in anti-static shipping bag.

ABBREVIATIONS

Frequently used abbreviations in this manual include:

CCN — Carrier Comfort Network CCW — Counterclockwise CHW — Chilled Water CHWR — Chilled Water Return CHWS — Chilled Water Supply CW — Clockwise ECW — Entering Chilled Water ECDW — Entering Condenser Water EMS — Energy Management System HGBP — Hot Gas Bypass I/O — Input/Output LCD — Liquid Crystal Display LCDW — Leaving Condenser Water LCW — Leaving Chilled Water LED — Light-Emitting Diode LID — Local Interface Device OLTA — Overload Trip Amps PIC — Product Integrated Control PSIO — Processor Sensor Input/

Output Module RLA — Rated Load Amps SCR — Silicon Control Rectiﬁer SMM — Starter Management Module TXV — Thermostatic Expansion Valve

17EX CHILLER FAMILIARIZATION

Chiller Identiﬁcation Label (Fig. 1) —

tiﬁcation label is located on the right side of the chiller control center panel. The label contains information on model number, refrigerant charge, rated voltage, etc.

The iden-

System Components (Fig. 2) — The components

include the cooler and condenser heat exchangers in separate vessels, compressor,compressorandgear lubrication packages, control center,speedincreasereconomizer/storage vessel, motor, and starter. The compressor drive consists of an external gear (speed increaser) and an electric motor. All connections from pressure vessels have external threads to enable each component to be pressure tested with a threaded pipe cap during factory assembly.

Cooler — This vessel (also known as the evaporator) is

located underneath the condenser, next to the economizer/ storage vessel. The cooler is maintained at lower temperature and pressure so that evaporating refrigerant can remove heat from water ﬂowing through its internal tubes.

Condenser — The condenser operates at a higher tem-

perature and pressure than the cooler and has water ﬂowing through its internal tubes in order to remove heat from the refrigerant.

Compressor — This component maintains system tem-

perature and pressure differences and moves the heatcarrying refrigerant from the cooler to the condenser.

Control Center — The control center is the user inter-

face for controlling the chiller and regulates the chiller capacity as required to maintain proper leaving chilled water temperature. The control center:

• registers cooler, condenser, and lubricating system pressures

• shows chiller operating and alarm shutdown conditions

• records the total chiller operating hours and how many hours the chiller has been running

• sequences chiller start, stop, and recycle under microprocessor control

• provides access to other CCN (Carrier Comfort Network) devices

MotorStarter (Purchased Separately) — The starter

allows the proper start and disconnect of electrical energy for the compressor-motor, oil pump, oil heater, and control panels.

Economizer/Storage Vessel — During normal op-

eration, this vessel functions as an economizer,returning flash gas to the second stage of the compressor and increasing the efficiency of the refrigeration cycle. During periods of shutdown and service, the economizer/storage vessel can serve as a storage tank for the refrigerant.

REFRIGERATION CYCLE (Fig. 3)

The 17EX chiller can be used to chill either water or brine. The data in this book applies to either application. Applications using corrosive brines may require using special tubes, tubesheet, and waterbox materials which are special order items.

Page 6

LEGEND NIH — Nozzle-In-Head *Any available cooler size can be combined with any available condenser size.

NOTE: For details on motor size designations, see below.

ASME

‘U’ STAMP

ARI (Air Conditioning

and Refrigeration

Institute)

PERFORMANCE

CERTIFIED

(60 Hz Only)

Fig. 1 — Model Number Identiﬁcation

Page 7

1 2 3 4 5 6 7 8 9 10 11 12 13 14

1—Condenser 2—Cooler Suction Pipe 3—Compressor Suction Elbow 4—Guide Vane Actuator 5—Condenser Discharge Pipe 6—Compressor Discharge Elbow 7—Two-Stage Compressor 8—Economizer Gas Line to Compressor

9—Compressor Housing Access Cover 10 — High-Speed Coupling (Hidden) 11 — External Gear (Speed Increaser) 12 — Low-Speed Coupling (Hidden) 13 — Open-Drive Compressor Motor 14 — Compressor Motor Terminal Box 15 — Low-Side Float Box Cover 16 — Gear Oil Pump 17 — Gear Oil Cooler/Filter 18 — Refrigerant Charging/Service Valve 19 — Refrigerant Liquid Line to Cooler 20 — Power Panel 21 — Oil Level Sight Glasses (2)

17EX WITH EXTERNAL GEAR (SPEED INCREASER)

Fig.2—Typical 17EX Chiller Components

LEGEND

22 — Oil Drain and Charging Valve 23 — Oil Heater (Hidden) 24 — Compressor Oil Pump 25 — Compressor Oil Cooler/Filter 26 — Local Interface Display Control Panel 27 — Cooler Relief Valves (Behind Compressor,

28 — Economizer Storage Vessel 29 — Economizer/Storage Vessel Relief Valves 30 — Pumpout Unit 31 — Cooler 32 — High Side Float Box Cover 33 — Cooler Waterbox Drain 34 — Take-Apart Connections 35 — Cooler Marine Waterbox 36 — Cooler Waterbox Vent 37 — Condenser Waterbox Drain 38 — Refrigerant Liquid Line to Economizer/

39 — Condenser Marine Waterbox 40 — Condenser Waterbox Vent

Hidden)

Storage Vessel

Page 8

The chiller compressor continuously draws large quantities of refrigerant vapor from the cooler at a rate determined by the amount of guide vane opening. This compressor suction reduces the pressure within the cooler, allowing the liquid refrigerant to boil vigorously at a fairly low temperature (typically 38 to 42 F [3 to 6 C]).

The liquid refrigerant obtains the energy needed to vaporize by removing heat from the water or brine in the cooler tubes. The cold water or brine can then be used in air conditioning and/or other processes.

After removing heat from the water or brine, the refrigerant vapor enters the ﬁrst stage of the compressor, is compressed, and ﬂows into the compressor second stage. Here it is mixed with ﬂash-economizer gas and is further compressed.

Compression raises the refrigerant temperature above that of the water ﬂowing through the condenser tubes. When the warm (typically 98 to 102 F [37 to 40 C]) refrigerant vapor comes into contact with the condenser tubes, the relatively cool condensing water (typically 85 to 95 F [29 to 35 C]) removes some of the heat, and the vapor condenses into a liquid.

The liquid refrigerant passes through an oriﬁce into the FLASC chamber.The coolest condenser water ﬂows through the FLASC and allows a lower saturated temperature and pressure. Part of the entering liquid refrigerant will ﬂash to vapor once it has passed through the FLASC oriﬁce, thereby cooling the remaining liquid. The vapor is then recondensed by the condenser water ﬂowing through the FLASC chamber.

The subcooled liquid refrigerant drains into a high-side valve chamber that meters the refrigerant liquid into a ﬂash economizer chamber. Pressure in this chamber is intermediate between condenser and cooler pressures. At this lower pressure, some of the liquid refrigerant ﬂashes to gas, further cooling the remaining liquid. The ﬂash gas, having absorbed heat, is returned directly to the compressor second stage. Here it is mixed with discharge gas that is already compressed by the ﬁrst-stage impeller. Since the ﬂash gas has to pass through only half the compression cycle to reach condenser pressure, there is a savings in power.

The cooled liquid refrigerant in the economizer is metered through the low-side valve chamber, reducing the refrigerant pressure. Pressure in the cooler is lower than in the economizer. Some of the liquid ﬂashes as it passes through the low side ﬂoat valve. The cycle is now complete.

OIL COOLING CYCLE

Compressor Oil Cooling —

water cooled. Water ﬂow through the oil cooler is manually adjusted by a plug valve to maintain an operating temperature at the reservoir of approximately 145 F (63 C). An oil heater in the reservoir helps to prevent oil from being diluted by the refrigerant. The heater is controlled by the PIC (Product Integrated Control) and is energized when the oil temperature is outside the operating temperature range of 150 to 160 F (66 to 71 C).

The compressor oil is

External Gear Oil Cooling — The external gear oil

is also water cooled. Water ﬂow through the gear oil cooler is manually adjusted by a plug valve to maintain an operating temperature of approximately 130 F (54 C). If so equipped, an oil heater in the reservoir helps to maintain the oil temperature under cold ambient operating conditions. The heater is controlled by an internal thermostat.

LUBRICATION CYCLE

Compressor Lubrication Cycle (Refer to item numbers shown in Fig. 4) —

pump and oil reservoir are contained in the compressor base. Oil is pumped through an oil cooler and ﬁlter to remove heat and any foreign particles. A portion of the oil is then directed to the shaft-end bearing and the shaft seal. The balance of the oil lubricates the thrust and journal bearings and the thrust end seal. The bearing and transmission oil returns directly to the reservoir to complete the cycle. Contact-seal oil leakage, however,iscollected in an atmospheric ﬂoat chamber to be pumped back to the main reservoir as the oil accumulates.

Oil may be charged into the compressor oil reservoir (Item 8) through a charging valve (Item 6) which also functions as an oil drain. If there is refrigerant in the chiller, however, a hand pump will be required for charging at this connection.

An oil-charging elbow (Item 3) on the seal-oil return chamber allows oil to be added without pumping. The seal-oil return pump (Item 4) automatically transfers the oil to the main reservoir. Sight glasses (11) on the reservoir wall permit observation of the oil level.

Amotor-drivenoil pump (Item 10) discharges oil to an oil cooler/ﬁlter (Item 16) at a rate and pressure controlled by an oil regulator (Item 10). The differential oil pressure (bearing supply versus oil reservoir) is registered on the control panel.

Water ﬂow through the oil cooler is manually adjusted by a plug valve (Item 17) to maintain the oil at an operating temperature of approximately 145 F (63 C). During shutdown, the oil temperature is also maintained at 150 to 160 F (65 to 71 C) by an immersion heater (Item 7) in order to minimize absorption of refrigerant by the oil.

Upon leaving the cooler section of the oil cooler/ﬁlter, the oil is ﬁltered (Item 15) and a portion is directed to the sealend bearing (Item 1) and the shaft seal (Item 2). The remainder lubricates thrust (Item 14) and journal bearings (Item 12). Thrust bearing temperature is indicated on the PIC controls. Oil from both circuits returns by gravity to the reservoir.

The shaft seal of the open compressor drive must be kept full of lubrication oil, even when the chiller is not operating, to prevent loss of refrigerant.

If the chiller is not operating and the oil pump has not operated during the last 12 hours, the control system automatically runs the oil pump for one minute in order to keep the contact seal ﬁlled with oil.

IMPORTANT: If the control power is to be deenergized for more than one day,the chiller refrigerant should be pumped over to the economizer/storage vessel.

The compressor oil

Page 9

LEGEND

TXV — Thermostatic Expansion Valve

*The FX compressor and the gear have a water cooled oil cooler.

Liquid Liquid/Vapor Vapor

Fig. 3 — Refrigeration, Cycle

External Gear Lubrication Cycle (Refer to Item numbers shown in Fig. 5) —

tained in the gear base.The external gear oil pump is mounted below the gear with the cooler/ﬁlter. Oil is pumped through an oil cooler/ﬁlter to remove heat and any foreign particles. A portion of the oil is directed to the gear bearings and gear mesh spray.The remainder is bypassed to the sump. The bearing and transmission oil returns directly to the reservoir to complete the cycle.

Oil may be charged into the external gear oil reservoir as described in the section, External Gear Pre-Start Checks, page 51. Observe the oil level in the oil level glass (Item 4) on the reservoir wall.

A motor driven oil pump (Item 10) discharges oil to the oil cooler/ﬁlter (Item 12). The pump has an internal pressure regulator to protect the pump in the event of an obstruction downstream. Water ﬂow through the oil cooler is manually adjusted by a plug valve (Item 14) to maintain the oil at an operating temperature of approximately 130 F (54 C).

Oil reservoir is con-

Upon leaving the cooler section (Item 13) of the oil cooler/ ﬁlter, the oil is ﬁltered (Item 11) and is directed to the pressure control valve (Item 7). Before entering the pressure control valve, the oil pressure (Item 16) and temperature (Item 8) are monitored by the PIC.

A portion of the oil then lubricates the gear bearings (Item 2). Another portion is directed through an oriﬁce (Item 5) to the gear mesh spray (Item 3) to lubricate the gear mesh (Item 1) during operation. Oil from both circuits returns by gravity to the reservoir.

STARTERS

All starters, whether supplied by Carrier or the customer, must meet Carrier Starter Speciﬁcation Z-375. This speciﬁcation can be obtained from a Carrier Sales Representative. The purpose of this speciﬁcation is to ensure the compatibility of the starter and the chiller.Many styles of compatible starters are available, including solid-state , auto-transformer, full-voltage, and, in the case of low-voltage main power supply, wye-delta closed transition.

Page 10

COMPRESSOR OIL PRESSURE LEAVING FILTER LINE

JOURNAL BEARING

CHECK VALVE

OIL FILTER

OIL COOLER/ FILTER

PLUG VALVE

SHAFT DISPLACEMENT & BRG TEMP. CUTOUT CONNECTIONS

TO PIC CONTROLLER

MAIN OIL RESERVOIR

THRUST BEARING

COAST DOWN RESERVOIRS

SEAL-END BEARING

SHAFT SEAL

OIL CHARGING ELBOW

SIGHT GLASSES

OIL PUMP & PRESS. REGULATOR

TO POWER PANEL

OIL THERMISTOR

OIL HEATER

DRAIN & CHARGING VALVE

Fig. 4 — 17EX Compressor Lubrication Cycle

COMPRESSOR OIL SUCTION PRESSURE

PUMP, SEAL OIL RETURN

Page 11

1—Gear Mesh 2—Bearings 3—Gear Mesh Spray 4—Oil Level Glass 5—Oriﬁce 6—Oil Supply Pressure

Transducer

7—Pressure Control Valve NOTE: The oil reservoir is at the base of the gear box.

Fig. 5 — External Gear Oil Lubrication Cycle (Plan View)

8—Oil Supply Temperature Thermistor

9—Oil Pump Motor 10 — Oil Pump and Pressure Regulator 11 — Oil Filter 12 — Oil Cooler/Filter 13 — Oil Cooler 14 — Plug Valve

CONTROLS

Deﬁnitions

ANALOG SIGNAL — An analog signal varies in proportion to the monitored source. It quantiﬁes values between operating limits. (Example: A temperature sensor is an analog device because its resistance changes in proportion to the temperature, generating many values.)

DIGIT ALSIGNAL— A digital (discrete) signal is a 2-position representation of the value of a monitored source. (Example: A switch is a digital device because it only indicates whether a value is above or below a set point or boundary by generating an on/off,high/low, or open/closed signal.)

VOLATILE MEMORY — Volatile memory is memory in- capable of being sustained if power is lost and subsequently restored.

The memories of the PSIO and LID modules are volatile. If the battery in a module is removed or damaged, all programming will be lost.

General — The 17EX externally geared open-drive cen-

trifugal liquid chiller contains a microprocessor-based control center that monitors and controls all operations of the chiller.The microprocessor control system matches the cooling capacity of the chiller to the cooling load while providing state-of-the-art chiller protection. The system controls cooling load within the set point plus the deadband by sensing the leaving chilled water or brine temperature and regulating the inlet guide vane via a mechanically linked actuator motor.The guide vane is a variable ﬂow prewhirl assembly that controls the refrigeration effect in the cooler by regulating the amount of refrigerant vapor ﬂow into the compressor.An increase in guide vane opening increases capacity.Adecrease in guide vane opening decreases capacity.Chiller protection is provided by the processor which monitors the digital and analog inputs and executes capacity overrides or safety shutdowns, if required.

Page 12

PIC System Components — The Product Integrated

Control (PIC) is the control system on the chiller. See T able1. The PIC controls the operation of the chiller by monitoring all operating conditions. The PIC can diagnose a problem and let the operator know what the problem is and what to check. It promptly positions the guide vanes to maintain leaving chilled water temperature. It can interface with auxiliary equipment such as pumps and cooling tower fans to turn them on only when required. It continually checks all safeties to prevent any unsafe operating condition. It also regulates the oil heater while the compressor is off and the hot gas bypass valve, if installed. See Fig. 6-10 for the locations of sensors, transducers, and other devices controlled and/or monitored by the PIC system.

The PIC can be interfaced with the Carrier Comfort Network (CCN) if desired. It can communicate with other PIC-equipped chillers and other CCN devices.

The PIC consists of 4 modules housed inside one of 3 locations: the control center, the power panel, or the starter cabinet. The component names and the control voltage of each location are listed below (also see Table 1):

• control center

— all extra low-voltage wiring (24 v or less)

REAR

• power panel — 115 v control voltage — up to 600 v for oil pump power

• starter cabinet — chiller power wiring (per job requirement)

Table 1 — Major PIC Components and

Panel Locations*

PIC COMPONENT

Processor Sensor Input/Output Module

(PSIO)

Starter Management Module (SMM) Starter Cabinet Local Interface Device (LID) Control Center 6-Pack Relay Board Control Center 8-Input Modules (Optional) Control Center 4-In/2-Out Module Power Panel Oil Differential Pressure/Power Supply

Module

Oil Heater Contactor (1C) Power Panel Compressor Oil Pump Contactor (2C) Power Panel Gear Oil Pump Contactor (5C) Power Panel Hot Gas Bypass Relay (3C) (Optional) Power Panel Control Transformers (T1-T4) Power Panel Control and Oil Heater Voltage Selector (S1) Power Panel Temperature Sensors See Fig. 7 Pressure Transducers See Fig. 7

*See Fig. 6-10.

PANEL

LOCATION

Control Center

1—Gear Oil Pressure Sensor 2—Thrust Bearing Temperature and

Impeller Displacement Cable

3—Discharge Temperature Sensor 4—Guide Vane Conduit and Cable 5—High Pressure Cutout Switch

LEGEND

6—Compressor Oil Cooler

Solenoid Conduit

7—Oil Heater Conduit 8—Motor Space Heater Conduit 9—Gear Oil Temperature Sensor

10 — Motor High Temperature Switch Cable

11 — Motor Water Cooling Leak Detector 12 — Discharge Oil Pressure Sensor

TEWAC — Totally Enclosed Water-to-Air Cooled

Fig. 6 — 17EX Controls and Sensor Locations

Cable (TEWAC Motor Only)

Page 13

LEGEND

13 — Condenser Pressure Transducer 14 — Condenser Entering Water

Temperature Sensor

15 — Condenser Entering and Leaving Water

Temperature Cable

16 — Oil Suction Pressure Sensor

17 — Oil Pump Conduit 18 — Oil Pump Sensor 19 — PIC Control Panel 20 — Condenser Leaving Water

Temperature Sensor

21 — Gear Oil Cooler Solenoid Conduit

LEGEND

22 — Cooler Temperature Cable 23 — Cooler Leaving Water Temperature Sensor 24 — Cooler Entering Water Temperature Sensor 25 — Cooler Pressure Sensor 26 — Refrigerant Charging Valve

Fig. 6 — 17EX Controls and Sensor Locations (cont)

Page 14

Fig. 6 — 17EX Controls and Sensor Locations (cont)

Fig. 7 — Control Sensors (Temperature)

Fig. 8 — Control Sensors

(Pressure Transducer, Typical)

LEGEND

LID — Local Interface Device PIC — Product Integrated Controls PSIO — Processor Sensor Input/Output Module

1—Optional 8-Input Module for Spare Inputs to Control

Interface (One of Two Available)

2—PSIO 3—LID Input/Output Interface Panel Display 4—Oil Differential Pressure/Power Supply Module (Hidden) 5—LID Light (Hidden) 6—6-Pack Relay Board 7—Circuit Breakers (4)

Fig. 9 — Control Center (Front View);

Shown with Options Module

Page 15

LEGEND

EQUIP GND — Equipment Ground GRD — Ground M—Motor TEWAC — Totally Enclosed Water-to-

Air Cooled

Fig. 10 — 17EX Chiller Power Panel and Controls Connections

Page 16

PROCESSOR/SENSOR INPUT/OUTPUT MODULE (PSIO) — This module contains all the operating software needed to control the chiller. The 17EX uses 5 pressure transducers and 8 thermistors to sense pressures and temperatures. These inputs are connected to the PSIO module. The PSIO also provides outputs to the guide vane actuator, compressor and gear oil pumps, oil heater, hot gas bypass (optional), and alarm contact. The PSIO communicates with the LID, the SMM, and the optional 8-input modules for user interface and starter management.

ST ARTER MANAGEMENT MODULE (SMM) — This module is located within the starter cabinet. This module initiates PSIO commands for starter functions such as start/ stop of the compressor; start/stop of the condenser and chilled water pumps; start/stop of the tower fan, spare alarm contacts, and the shunt trip. The SMM monitors starter inputs such as ﬂow switches, line voltage, remote start contact, spare safety, condenser high pressure, oil pump interlock, motor current signal, starter 1M and run contacts, and the kW transducer input (optional). The SMM contains logic capable of safely shutting down the chiller if communication with the PSIO is lost.

LOCALINTERFACE DEVICE (LID) — The LID is mounted to the control center and allows the operator to interface with the PSIO or other CCN devices. It is the input center for all local chiller set points, schedules, set-up functions, and options. The LID has a STOP button, an alarm light, 4 buttons for logic inputs, and a display. The function of the 4 buttons or ‘‘softkeys’’ are menu driven and are shown on the display directly above the key.

SIX-PACK RELAY BOARD (6-Pack Relay Board) — This device is a cluster of 6 pilot relays located in the control center. It is energized by the PSIO for the compressor oil pump, oil heater, alarm, optional hot gas bypass relay, auxiliary oil pump.

EIGHT-INPUT (8-Input) MODULES — One optional module is factory installed in the control center panel when ordered. There can be up to 2 of these modules per chiller with 8 spare inputs each. They are used whenever chilled water reset, demand reset, or reading a spare sensor is required. The sensors or 4 to 20 mA signals are ﬁeld-installed.

The spare temperature sensors must have the same temperature/resistance curve as the other temperature sensors on this unit. These sensors are rated 5,000 ohm at 75 F (25 C).

FOUR-IN/TWO-OUT(4-IN/2-OUT) MODULE —Thismodule monitors and controls the external gear lubrication system. It energizes the gear oil pump and is located in the power panel.

OIL HEATER CONTACTOR (1C) — This contactor is located in the power panel and operates the heater at 115 v. It is controlled by the PIC to maintain oil temperature during chiller shutdown.

COMPRESSOR OILPUMP CONTACTOR(2C)ANDGEAR OIL PUMP CONTACTOR (5C) — These contactors are located in the power panel. They operate all 200 to 575-v oil pumps. The PIC energizes the contactor to turn on the oil pumps as necessary.

HOT GAS BYPASS CONTACTOR RELAY (3C) (Optional) — This relay, located in the power panel, controls the opening of the hot gas bypass valve. The PIC energizes the relay during low load, high lift conditions.

OIL AUXILIARY RELAY (4C) — This relay opens the oil cooler solenoid valve and interlocks the oil pump with the compressor (special order).

CONTROL TRANSFORMERS (T1-T4) — These transformers are located in the power panel and convert

incoming control voltage to either 21 vac power for the PSIO module and options modules, or 24 vac power for 3 power panel contactor relays and a control solenoid valve.

CONTROL AND OIL HEATER VOLTAGE SELECTOR (S1) — It is necessary to use 115 v incoming control power in the power panel. The switch must be set to the 115-v position.

OIL DIFFERENTIAL PRESSURE/POWER SUPPLY MODULE — This module, which is located in the control center, provides 5 vdc power for the transducers and LID backlight. This module outputs the difference between two pressure transducer input signals. The module subtracts oil supply pressure from transmission sump pressure and outputs the difference as an oil differentialpressure signal to the PSIO. The PSIO converts this signal to differential oil pressure. To calibrate this reading, refer to the Troubleshooting, Checking Pressure Transducers section on page 84.

LID Operation and Menus (Fig. 11-17)

GENERAL

• The LID display automatically reverts to the default screen (Fig. 11) after 15 minutes if no softkey activity takes place and if the chiller is not in PUMPDOWN mode

• When not displaying the default screen, the upper righthand corner of the LID displays the name of the screen that you have entered (Fig. 12).

• The LID may be conﬁgured in English or SI units, through the LID conﬁguration screen.

• Local Operation — Pressing the LOCAL the PIC in LOCAL operation mode, and the control ac-

cepts modiﬁcation to programming from the LID only. The PIC uses the Local Time Schedule to determine chiller start and stop times.

• CCN Operation — Pressing the CCN softkey places the PIC in the CCN operation mode, and the control accepts

modiﬁcations from any CCN interface or module (with the proper authority), as well as the LID. The PIC uses the CCN time schedule to determine start and stop times.

Fig. 11 — LID Default Screen

ALARMS AND ALERTS — An alarm (*) or alert (!) status is indicated on the default screen and the status tables. An alarm (*) shuts down the compressor. An alert (!) notiﬁes the operator that an unusual condition has occurred. The chiller continues to operate when an alert is shown.

Alarms are indicated when the control center alarm light (!) ﬂashes. The primary alarm message is viewed on the default screen and an additional, secondary, message and troubleshooting information are sent to the ALARM HISTORY table.

softkey places

Page 17

NOTE: When an alarm is detected, the LID default screen freezes (stops updating) at the time of alarm. The freeze enables the operator to view the chiller conditions at the time of the alarm. The status tables show the updated informa-

tion. Once all alarms have been cleared (by pressing the

RESET

softkey), the default LID screen returns to normal

operation.

Fig. 12 — LID Service Screen

LID DEFAULT SCREEN MENU ITEMS — To perform any of the operations described below, the PIC must be powered up and have successfully completed its self test.

The default screen menu selection offers four options (STATUS, SCHEDULE, SETPOINT, and SERVICE). The STATUS menu allows viewing and limited calibration/ modiﬁcation of control points and sensors, relays and contacts, and the options board. The SCHEDULE menu allows viewing and modiﬁcation of the Local Control, CCN Control, and Ice Build time schedules. Numerous set points including Base Demand Limit, LCW, ECW, and Ice Build can be adjusted under the SETPOINT menu. The SERVICE menu can be used to revise alarm history, control test, control algorithm status, equipment conﬁguration, equipment service, time and date, attach to network, log out of device, controller identiﬁcation, and LID conﬁgurations. Figures 15 and 16 provide additional information on the menu structure.

Press the MENU

softkey to select from the 4 options. To view or change parameters within any menu structure, use the SELECT

softkey to choose the desired table or

item. The softkey modiﬁcation choices displayed will depend on whether the selected item is a discrete point, analog point, or an override point. Press the softkey that corresponds to your conﬁguration selection or press the

QUIT softkey. If the QUIT softkey is depressed, the

conﬁguration will not be modiﬁed. Use the following softkeys to access and select the desired section.

MENU STRUCTURE — To perform any of the operations described below, the PIC must be powered up and have successfully completed its self test.

• Press MENU

to select from the four available options.

• Press NEXT or PREVIOUS to highlight the desired entry.

• Press SELECT to access the highlighted point.

• Press QUIT to leave the selected decision or ﬁeld without saving any changes.

• Or, press ENTER to leave the selected decision or ﬁeld and save changes.

TOVIEWOR CHANGE POINT STATUS (Fig. 13) — Point Status is the actual value of all of the temperatures, pressures, relays, and actuators sensed and controlled by the PIC.

1. On the Menu screen, press STATUS

to view the list of

Point Status tables.

2. Press NEXT or PREVIOUS to highlight the desired

status table. The list of tables is:

• STATUS01 — Status of control points and sensors

• STATUS02 — Status of relays and contacts

• STATUS03 — Status of both optional 8-input modules and sensors

• STATUS04 — Gear oil temperature and pressure

• Press the softkey that corresponds to the desired menu structure.

Fig. 13 — Example of Point Status Screen

(Status01)

Page 18

3. Press SELECT to view the desired Point Status table.

4. On the Point Status table press NEXT or PREVIOUS

until desired point is displayed on the screen.

Override Indication — An override value is indicated by ‘ ‘SUPVSR,’’‘‘SERVC,’’or ‘‘BEST’’ ﬂashing next to the point value on the Status table.

TO VIEW OR CHANGE TIME SCHEDULE OPERATION (Fig. 14)

1. On the Menu screen, press SCHEDULE

For Discrete Points — Press START or STOP ,

or NO ,ONor OFF , etc. to select the desired

YES

state.

For Analog Points — Press INCREASE or

DECREASE

to select the desired value.

5. Press ENTER to register new value.

OVERRIDE OPERATIONS NOTE: When overriding or changing metric values, it is nec-

essary to hold the softkey down for a few seconds in order to see a value change, especially on kilopascal values.

To Remove an Override

1. On the Point Status table press NEXT or PREVIOUS

to highlight the desired point.

2. Press NEXT or PREVIOUS to highlight one of the following schedules.

OCCPC01S — LOCAL Time Schedule OCCPC02S — ICE BUILD Time Schedule OCCPC03-99S — CCN Time Schedule (Actual

number is deﬁned in CONFIG table.)

3. Press SELECT to access and view the time schedule.

4. Press NEXT or PREVIOUS to highlight the desired period or override that you wish to change.

5. Press SELECT to access the highlighted period or override.

2. Press SELECT to access the highlighted point.

3. Press RELEASE to remove the override and return the point to the PIC’s automatic control.

Fig. 14 — Example of Time Schedule

Operation Screen

Page 19

CCN

Start Chiller In CCN Control

Start Chiller In Local Control

DEFAULT SCREEN

LOCAL RESET

(SOFTKEYS)

Clear Alarms

START

INCREASE

ENABLE

STATUS

List the Status Tables

STATUS STATUS STATUS STATUS

STOP RELEASE

DECREASE

DISABLE

SCHEDULE SETPOINT

01 02 03 04

SELECT

RELEASE

Access Main Menu

SERVICE

EXIT

ENTER

(SELECT A T ABLE) (SELECT A POINT

ON THE TABLE) (MODIFY A

DISCRETE POINT) or (MODIFY AN

ANALOG POINT) or (MODIFY CONTROL

OPTIONS)

Select a Schedule

Select a Time Period/Override

Modify a Schedule Time

INCREASE

Add/Eliminate a Day

ENABLE

123

List the Schedules

OCCPC01S - Local Time Schedule OCCPC02S - Ice Build Time Schedule OCCPC03S-99S - CCN Time Schedule

(ENTER A 4-DIGIT PASSWORD)

Select the Setpoint

Modify the Setpoint

1 2 3 4 5 6 7 8

Override

SELECT

ENTER

DECREASE

DISABLE

Display the Setpoint Table

INCREASE

•

Base Demand Limit

•

LCW Setpoint

•

ECW Setpoint

•

Ice Build Setpoint

DECREASE

EXIT

(ANALOG VALUES)

(DISCRETE VALUES)

List the Service Tables

SELECT

QUIT

EXIT

ENTER

Select a Service Table

Fig. 15 — 17EX LID Menu Structure

• ALARM HISTORY

• CONTROL TEST

• CONTROL ALGORITHM STATUS

• EQUIPMENT CONFIGURATION

• EQUIPMENT SERVICE

• TIME AND DATE

• ATTACH TO NETWORK DEVICE

• LOG OUT OF DEVICE

• CONTROLLER IDENTIFICATION

• LID CONFIGURATION

SEE FIGURE 16

SELECT

EXIT

Page 20

SERVICE TABLE

ALARM HISTORY

CONTROL TEST

CONTROL ALGORITHM STA TUS

List the Control Algorithm Status Tables

MAINT01 (Capacity Control) MAINT02 (Override Status) MAINT03 (Surge/HGBP Status) MAINT04 (Lead/Lag Status) WSMDEFME (Water System Manager Control Status) OCCDEFM (Time Schedule Status)

SELECT

Display Alarm History

(The table holds up to 25 alarms and alerts with the last alarm at the top of the screen.)

EXIT

List the Control Tests

Select a Test

• Automated T est

• PSIO Thermistors

• Options Thermistor

• Transducers

• Guide Vane Actuator

• Pumps

• Discrete Outputs

• Pumpdown Lockout

• Terminated Lockout

• FX Gear Oil Pump I/O

SELECT

EXIT

Select a Table:

OCCDEFM (Time Schedule Status)

Data Select Table

EQUIPMENT CONFIGURATION List the Equipment Configuration Tables

OCCPC01S (Local Status) OCCPC02S (CCN, ICE BUILD Status) OCCPC03S (CCN Status)

SELECT

EXIT

MAINT01 (Capacity Control Algorithm) MAINT02 (Override Status)\ MAINT03 (Surge/HGBP Status) MAINT04 (LEAD/LAG Status) WSMDEFM2 (Water System Manager Control Status)

EXIT

Maintenance T able Data

• CONFIG

• LEAD/LAG

• OCCDEFCS

• HOLIDEF

• BRODEF

• WSMALMDF

• ALARMDEF

• CONS_DEF

• RUNT_DEF

Select a Table

SELECT

EXIT

CONTINUED ON NEXT PAGE

Select a Parameter

Modify a Parameter

INCREASE

ENABLE

YES

DECREASE

DISABLE

Fig. 16 — 17EX Service Menu Structure

SELECT

QUIT QUIT QUIT

EXIT

ENTER ENTER ENTER

(ANALOG VALUES)

(DISCRETE VALUES)

Page 21

SERVICE MENU CONTINUED FROM PREVIOUS PAGE

EQUIPMENT SERVICE (See Table 2, Examples 8, 9, and 10)

Service Tables: (See Note)

• SERVICE1

• SERVICE2

• SERVICE3

Select a Service Table

Select a Service Table Parameter

Modify a Service Table Parameter

INCREASE

ENABLE

TIME AND DATE

ATTACH TO NETWORK DEVICE

Select a Device

Modify Device Address

INCREASE

• Use to attach LID to another CCN network or device

• Attach to "LOCAL" to enter this machine

• To upload new tables

DECREASE

DISABLE

YES

List Network Devices

• Local

• Device 1

• Device 2

• Device 3

• Device 4

• Device 5

DECREASE

SELECT

QUIT QUIT QUIT

• Device 6

• Device 7

• Device 8

• Device 9

SELECT

ENTER

EXIT

ENTER ENTER ENTER

ATTACH

EXIT

(ANALOG VALUES) (DISCRETE VALUES) (DISCRETE VALUES)

Display Time and Date Table:

• To Modify — Time — Day of Week

INCREASE

DECREASE

— Date — Holiday Today

ENTER

EXIT

LOG OUT OF DEVICE

CONTROLLER IDENTIFICATION PSIO Controller

Identification Table

INCREASE

• To modify — PSIO CCN Address • To View — PSIO Software Version

LID CONFIGURATION

DECREASE

LEGEND

CCN — Carrier Comfort Network HGBP — Hot Gas Bypass LID — Local Interface Device

NOTE: SERVICE TABLES:

SERVICE1: — Capacity Override

— Type of Chilled Medium — Alert Temperature — Flow Veriﬁcation — Deadband — Recycle Restart Time — Surge/HGBP Operation — Motor Voltage, RLA, and Frequency — Starter Type — Condenser Freeze Safety — Soft Stop Conﬁguration — Start to Stop Timer — Gear Oil Pump Conﬁguration

ENTER

Default Screen

CCN

EXIT

(last 2 digits on part number indicate software version)

LID Configuration Table

INCREASE

• To Modify — LID CCN Address

LOCAL

DECREASE

— English or S.I. Metric Units — Password

RESET

ENTER

SERVICE2: — 8-input Modules

SERVICE3: — Proportional Inc each Band

— 20 mA Power Source

— Proportional Dec each Band — Proportional ECW Gain — Maximum Guide Vane Opening

EXIT

• To View — LID Software Version (last 2 digits of part number

indicate software version)

Fig. 16 — 17EX Service Menu Structure (cont)

Page 22

6. a. Press INCREASE or DECREASE to change the time values. Override values are in one-hour incre-

ments, up to 4 hours.

b. Press ENABLE to select days in the day-of-week

ﬁelds. Press DISABLE

to eliminate days from the

period.

7. Press ENTER to register the values and to move horizontally (left to right) within a period.

8. Press EXIT to leave the period or override.

9. Either return to Step 4 to select another period or override, or press EXIT

again to leave the cur-

rent time schedule screen and save the changes.

4. Press SELECT to modify the highlighted set point.

5. Press INCREASE or DECREASE to change the selected set point value.

6. Press ENTER to save the changes and return to the previous screen.

10. Holiday Designation (HOLIDEF table) may be found in the Service Operation section, page 42.You must assign the month, day, and duration for the holiday.The Broadcast function in the BRODEF table also must be enabled for holiday periods to function.

TO VIEW AND CHANGE SET POINTS (Fig. 17)

1. To view the Set Point table, at the Menu screen press

SETPOINT

2. There are 4 set points on this screen: Base Demand Limit;

LCW Set Point (leaving chilled water set point); ECW Set Point (entering chilled water set point); and ICE BUILD set point. Only one of the chilled water set points can be active at one time, and the type of set point is activated in the Service menu. ICE BUILD is also activated and conﬁgured in the Service menu.

3. Press NEXT or PREVIOUS to highlight the desired

set point entry.

Fig. 17 — Example of Set Point Screen

SERVICE OPERATION — To view the menu-driven programs available for Service Operation, see the Service Operation section, page 42. For examples of LID display screens, see Table 2.

LEGEND FOR TABLE 2 — LID DISPLAY DATA

CCN — Carrier Comfort Network CHWR — Chilled Water Return CHWS — Chilled Water Supply Compr — Compressor Dec — Decrease Ecw — Entering Chilled Water HGBP — Hot Gas Bypass Inc — Increase LCW — Leaving Chilled Water mA — Milliamps P—Pressure PIC — Product Integrated Controls Refrig — Refrigerant T—Temperature Temp — Temperature

Page 23

Table 2 — LID Display Data

NOTES:

IMPORTANT: The following notes apply to all Table 2 examples.

1. Only 12 lines of information appear on the LID screen at any one time. Pressthe NEXT or to view items below or above the current screen. If you have a chiller with a backlit LID, press the NEXT forward; press the PREVIOUS

2. Toaccess the information shown in Examples 6 through 14, enter your 4-digit password after pressing the SERVICE

softkeys arepressed for 15 minutes, the LIDautomatically logs off (to prevent unrestricted access to PIC controls) and reverts to the default screen. If this happens, you must reenter your password to access the tables shown in Examples 6 through 14.

3. Termsin the Description column of these tables are listed as they appear on the LID screen.

4. The LID may be conﬁgured in English or Metric (SI) units using theLIDCONFIGURATIONscreen. See the ServiceOperation section, page 42, for instructions on making this change.

To access this display from the LID default screen:

1. Press MENU

2. Press STATUS

3. Press SELECT

or PREVIOUS softkey to highlightapoint

softkey twice to page

softkey twice to page back.

softkey.If no

EXAMPLE1—STATUS01 DISPLAY SCREEN

. (STATUS01 will be highlighted).

5. The items in the Reference Point Name column

the LID screen

Building Supervisor software. They are listed in these tables as a convenience to the operator if it is necessary to cross reference CCN/BS documentation or use CCN/BS programs. For more information, see the 17EX CCN literature.

6. Reference Point Names shown in these tables in all capital letters can be read by CCN and Building Supervisor software. Of these capitalized names, those preceded by an asterisk can also be changed (that is, written to) by the CCN, Building Supervisor software and the LID. Capitalized Reference Point Names preceded by two asterisks can be changed only from the LID. Reference Point Names in lower case type can be viewed by CCN or Building Supervisor software only by viewing the whole table.

7. Alarms and Alerts: An asterisk

screen

tion point in the far right ﬁeld of the LID screen indicates an alert state. The asterisk (or exclamation point) indicates that the value on that line has exceeded (or is approaching) a limit. For more information on alarms and alerts, see the Alarms and Alerts section, page 16.

. They are data or variable names used in CCN or

in the far right ﬁeld of a LID status

indicates that the chiller is in an alarm state; an exclama-

do not appear on

DESCRIPTION RANGE UNITS

Control Mode Reset.Off. Local. CCN MODE Run Status Timeout. Recycle. Startup. STATUS

Occupied ? No/Yes OCC Alarm State Normal/Alarm ALM *Chiller Start/Stop Stop/Start CHIL S S Base Demand Limit 40-100 % DLM *Active Demand Limit 40-100 % DEM LIM Compressor Motor Load 0-999 % CA L

Current 0-999 % CA P

Amps 0-9999 AMPS CA A *Target Guide Vane Pos 0-100 % GV TRG Actual Guide Vane Pos 0-100 % GV ACT Water/Brine: Setpoint 10-120 (–12.2-48.9) DEG F (DEG C) SP * Control Point 10-120 (–12.2-48.9) DEG F (DEG C) LCW STPT Entering Chilled Water –40-245 (–40-118) DEG F (DEG C) ECW Leaving Chilled Water –40-245 (–40-118) DEG F (DEG C) LCW Entering Condenser Water –40-245 (–40-118) DEG F (DEG C) ECDW Leaving Condenser Water –40-245 (–40-118) DEG F (DEG C) LCDW Evaporator Refrig Temp –40-245 (–40-118) DEG F (DEG C) ERT Evaporator Pressure –6.7-420 (–46-2896) PSI (kPa) ERP Condenser Refrig Temp –40-245 (–40-118) DEG F (DEG C) CRT Condenser Pressure –6.7-420 (–46-2896) PSI (kPa) CRP Discharge Temperature –40-245 (–40-118) DEG F (DEG C) CMPD Bearing Temperature –40-245 (–40-118) DEG F (DEG C) MTRB Motor Winding Temp† –40-245 (–40-118) DEG F (DEG C) MTRW Motor Winding Hi

Temp Cutout

Oil Sump Temperature –40-245 (–40-118) DEG F (DEG C) OILT Oil Pressure Transducer† –6.7-420 (–46-2896) PSI (kPa) OILP Oil Pressure** –6.7-420 (–46-2896) PSID (kPad) OILPD Line Voltage: Percent 0-999 % V P

*Remote Contacts Input Off/On REMCON Total Compressor Starts 0-65535 c starts Starts in 12 Hours 0-8 STARTS Compressor Ontime 0-500000.0 HOURS c hrs *Service Ontime 0-32767 HOURS S HRS *Compressor Motor kW 0-9999 kW CKW

†Information is applicable to hermetic chillers (19EX) only.

**Oil pressure is read directly from a differential pressure module on 17EX chillers. NOTE: values preceded by an asterisk (*) can be forced (changed by an operator) from the LID screen

or from another control device (such as a Carrier Comfort Network [CCN] terminal).

Actual 0-9999 VOLTS V A

Ramping. Running. Demand. Override. Shutdown. Abnormal. Pumpdown

Normal/Alarm MTRW

REFERENCE POINT NAME

(ALARM HISTORY)

Page 24

EXAMPLE2—STATUS02 DISPLAY SCREEN

To access this display from the LID default screen:

1. Press MENU

2. Press STATUS

3. Scroll down to highlight STATUS02.

4. Press SELECT

Table 2 — LID Display Data (cont)

DESCRIPTION

Hot Gas Bypass Relay X OFF/ON HGBR *Chilled Water Pump X OFF/ON CHWP Chilled Water Flow X NO/YES EVFL *Condenser Water Pump X OFF/ON CDP Condenser Water Flow X NO/YES CDFL Compressor Start Relay X OFF/ON CMPR Compressor Start Contact X OPEN/CLOSED 1CR AUX Compressor Run Contact X OPEN/CLOSED RUN AUX Starter Fault Contact X OPEN/CLOSED STR FLT Pressure Trip Contact X OPEN/CLOSED PRS TRIP Single Cycle Dropout X NORMAL/ALARM V1 CYCLE Oil Pump Relay X OFF/ON OILR Oil Heater Relay X OFF/ON OILH Motor Cooling Relay† X OFF/ON MTRC Auxiliary Oil Pump Relay X OFF/ON AUXOILR *Tower Fan Relay X OFF/ON TFR Compr. Shunt Trip Relay X OFF/ON TRIPR Alarm Relay X NORMAL/ALARM ALM Spare Prot Limit Input X ALARM/NORMAL SPR PL

†Information is applicable to hermetic machines only. NOTE: values preceded by an asterisk (*) can be forced (changed by an operator) from the LID screen

or from another control device (such as a Carrier Comfort Network [CCN] terminal).

To access this display from the LID default screen:

1. Press MENU

2. Press STATUS

3. Scroll down to highlight STATUS03.

4. Press SELECT

POINT TYPE

INPUT OUTPUT

EXAMPLE3—STATUS03 DISPLAY SCREEN

UNITS

REFERENCE POINT NAME

(ALARM HISTORY)

DESCRIPTION RANGE UNITS

OPTIONS BOARD 1 *Demand Limit 4-20 mA 4-20 mA DEM OPT

*Temp Reset 4-20 mA 4-20 mA RES OPT *Common CHWS Sensor –40-245 (–40-118) DEG F (DEG C) CHWS *Common CHWR Sensor –40-245 (–40-118) DEG F (DEG C) CHWR *Remote Reset Sensor –40-245 (–40-118) DEG F (DEG C) R RESET *Temp Sensor — Spare 1 –40-245 (–40-118) DEG F (DEG C) SPARE1 *Temp Sensor — Spare 2 –40-245 (–40-118) DEG F (DEG C) SPARE2 *Temp Sensor — Spare 3 –40-245 (–40-118) DEG F (DEG C) SPARE3

OPTIONS BOARD 2 *4-20 mA — Spare 1 4-20 mA SPARE1 M

*4-20 mA — Spare 2 4-20 mA SPARE2 M *Temp Sensor — Spare 4 –40-245 (–40-118) DEG F (DEG C) SPARE4 *Temp Sensor — Spare 5 –40-245 (–40-118) DEG F (DEG C) SPARE5 *Temp Sensor — Spare 6 –40-245 (–40-118) DEG F (DEG C) SPARE6 *Temp Sensor — Spare 7 –40-245 (–40-118) DEG F (DEG C) SPARE7 *Temp Sensor — Spare 8 –40-245 (–40-118) DEG F (DEG C) SPARE8 *Temp Sensor — Spare 9 –40-245 (–40-118) DEG F (DEG C) SPARE9

NOTE: values preceded by an asterisk (*) can be forced (changed by an operator) from the LID screen or from another control device (such as a Carrier Comfort Network [CCN] terminal).

REFERENCE POINT NAME

(ALARM HISTORY)

Page 25

EXAMPLE4—STATUS04 DISPLAY SCREEN

To access this display from the LID default screen:

1. Press MENU

2. Press STATUS

3. Scroll down to highlight STATUS04.

4. Press SELECT

Table 2 — LID Display Data (cont)

DESCRIPTION RANGE UNITS

Main Gear Oil Pump OFF/ON MAINPMP1 Auxiliary Gear Oil Pump OFF/ON AUXPMP2 Gear Oil Pressure −6.7 to 420 (−46 to 2896) psi (kPa) GEAROILP Gear Oil Temperature −40 to 245 (−40 to 118) DEG F (DEG C) GEAROILT

EXAMPLE 5 — SETPOINT DISPLAY SCREEN

To access this display from the LID default screen:

1. Press MENU

2. Press SETPOINT

DESCRIPTION CONFIGURABLE RANGE UNITS REFERENCE POINT NAME DEFAULT VALUE

Base Demand Limit 40-100 % DLM 100 LCW Setpoint 20-120 (–6.7-48.9) DEG F (DEG C) lcw sp ECW Setpoint 20-120 (–6.7-48.9) DEG F (DEG C) ecw sp 60.0 (15.6) ICE BUILD Setpoint 20- 60 (–6.7-15.6) DEG F (DEG C) ice sp

REFERENCE POINT NAME

(ALARM HISTORY)

50.0 (10.0)

40.0 ( 4.4)

Page 26

Table 2 — LID Display Data (cont)

EXAMPLE 6 — CONFIGURATION (CONFIG) DISPLAY SCREEN

To access this display from the LID default screen:

1. Press MENU

2. Press SERVICE

3. Scroll down to highlight EQUIPMENT CONFIGURATION.

4. Press SELECT

5. Scroll down to highlight CONFIG.

6. Press SELECT

DESCRIPTION CONFIGURABLE RANGE UNITS REFERENCE POINT NAME DEFAULT VALUE

RESET TYPE 1 Degrees Reset at 20 mA –30-30 (–17-17) DEG F (DEG C) deg 20ma

RESET TYPE 2 Remote Temp (No Reset) –40-245 (–40-118) DEG F (DEG C) res rt1 Remote Temp (Full Reset) –40-245 (–40-118) DEG F (DEG C) res rt2 65 (18) Degrees Reset –30-30 (–17-17) DEG F (DEG C) res rt 10D(6D)

RESET TYPE 3 CHW Delta T (No Reset) 0-15 (0-8) DEG F (DEG C) restd 1 CHW Delta T (Full Reset) 0-15 (0-8) DEG F (DEG C) restd 2 0D(0D) Degrees Reset –30-30 (–17-17) DEG F (DEG C) deg chw 5D(3D)

Select/Enable Reset Type 0-3 res sel ECW CONTROL OPTION DISABLE/ENABLE ecw opt

Demand Limit At 20 mA 40-100 % dem 20ma 40 20 mA Demand Limit Option DISABLE/ENABLE dem sel DISABLE

Auto Restart Option DISABLE/ENABLE astart DISABLE Remote Contacts Option DISABLE/ENABLE r contact Temp Pulldown Deg/Min 2-10 tmp ramp

Load Pulldown %/Min 5-20 kw ramp 10 Select Ramp Type: 0/1 ramp opt 1

Temp=0,Load=1

Loadshed Group Number 0-99 ldsgrp 0 Loadshed Demand Delta 0-60 % ldsdelta 20 Maximum Loadshed Time 0-120 MIN maxldstm 60

CCN Occupancy Conﬁg:

Schedule Number 3-99 occpcxxe 3 Broadcast Option DISABLE/ENABLE occbrcst DISABLE

ICE BUILD Option DISABLE/ENABLE ibopt DISABLE ICE BUILD TERMINATION

0 =Temp, 1 =Contacts, 2 =Both 0-2 ibterm 0

ICE BUILD Recycle Option DISABLE/ENABLE ibrecyc DISABLE

NOTE: D = delta degrees.

10D(6D) 85 (29)

10D(6D)

0 DISABLE

DISABLE 3

Page 27

Table 2 — LID Display Data (cont)

EXAMPLE 7 — LEAD/LAG CONFIGURATION DISPLAY SCREEN

To access this display from the LID default screen:

1. Press MENU

2. Press SERVICE

3. Scroll down to highlight EQUIPMENT CONFIGURATION.

4. Press SELECT

5. Scroll down to highlight LEAD/LAG.

6. Press SELECT

DESCRIPTION CONFIGURABLE RANGE UNITS REFERENCE POINT NAME DEFAULT VALUE

LEAD/LAG SELECT

DISABLE =0, LEAD =1, LAG =2, STANDBY =3

Load Balance Option DISABLE/ENABLE loadbal DISABLE Common Sensor Option DISABLE/ENABLE commsens DISABLE LAG Percent Capacity 25-75 % lag per LAG Address 1-236 lag add LAG START Timer 2-60 MIN lagstart 10 LAG STOP Timer 2-60 MIN lagstop 10 PRESTART FAULT Timer 0-30 MIN preﬂt 5 STANDBY Chiller Option DISABLE/ENABLE stndopt DISABLE STANDBY Percent Capacity 25-75 % stnd per STANDBY Address 1-236 stnd add

LEAD/LAG CONFIGURATION SCREEN

0-3 leadlag 0

50 92

50 93

Page 28

Table 2 — LID Display Data (cont)

EXAMPLE 8 — SERVICE1 DISPLAY SCREEN

To access this display from the LID default screen:

1. Press MENU

2. Press SERVICE

3. Scroll down to highlight EQUIPMENT SERVICE.

4. Press SELECT

5. Scroll down to highlight SERVICE1.

6. Press SELECT

DESCRIPTION CONFIGURABLE RANGE UNITS REFERENCE POINT NAME DEFAULT VALUE

Motor Temp Override* 150-200 (66-93) DEG F (DEG C) mt over Cond Press Override 90-200 (620-1379) PSI (kPa) cp over Refrig Override Delta T 2-5 (1-3) DEG F (DEG C) ref over 3D (1.6D) Chilled Medium Water/Brine medium WATER Brine Refrig Trippoint 8-40 (–13.3-4) DEG F (DEG C) br trip

Compr Discharge Alert 125-200 (52-93) DEG F (DEG C) cd alert Bearing Temp Alert 165-210 (74-99) DEG F (DEG C) tb alert 175 (79)

Water Flow Verify Time 0.5-5 MIN wﬂow t Oil Press Verify Time 15-300 SEC oilpr t 15

Water/Brine Deadband 0.5-2.0 (0.3-1.1) DEG F (DEG C) cw db Recycle Restart Delta T 2.0-10.0 (1.1-5.6) DEG F (DEG C) rcycrdt 5 (2.8) Recycle Shutdown Delta 0.5-4.0 (.27-2.2) rcycsdt 1.0 (0.6) Surge Limit/HGBP Option 0/1 srg hgbp Select: Surge=0, HGBP=1 Surge/HGBP Delta T1 0.5-15 (0.3-8.3) DEG F (DEG C) hgb dt1 Surge/HGBP Delta P1 30-170 (207-1172) PSI (kPa) hgb dp1 50 (345) Min. Load Points (T1/P1) Surge/HGBP Delta T2 0.5-15 (0.3-8.3) DEG F (DEG C) hgb dt2 Surge/HGBP Delta P2 30-170 (207-1172) PSI (kPa) hgb dp2 85 (586) Full Load Points (T2/P2) Surge/HGBP Deadband 1-3 (0.6-1.6) DEG F (DEG C) hgb dp

Surge Delta Percent Amps 10-50 % surge a Surge Time Period 1-5 MIN surge t 2

Demand Limit Source 0/1 dem src Select: Amps=0, Load=1 Amps Correction Factor 1-8 corfact 3 Motor Rated Load Amps 1-9999 AMPS a fs Motor Rated Line Voltage 1-9999 VOLTS v fs 460 Meter Rated Line kW 1-9999 kW kw fs 600

Line Frequency 0/1 HZ freq 0 Select: 0=60 Hz, 1=50 Hz

Compr Starter Type REDUCE/FULL starter REDUCE Condenser Freeze Point –20-35 (–28.9-1.7) DEG F (DEG C) cdfreeze 34 (1) Soft Stop Amps Threshold 40-100 % softstop 100 Stop to Start Timer 3-50 MIN stopmtr 20

External Gear Option ENABLE/DSABLE exg opt Mechanical Gear Oil Pump ENABLE/DSABLE mech pmp DSABLE Auxiliary Gear Oil Pump ENABLE/DSABLE aux pmp Gear Oil Pressure Alert 15-20 (103-138) PSI (kPa) gearp al 15 (103) Gear Oil Temperature Alert 130-145 (54-63) DEG F (DEG C) geart al 130 (54)

*Information is applicable to hermetic machines (19EX) only. NOTE: D = delta degrees.

200 (93) 125 (862)

33 (1) 200 (93)

1.0 (0.6)

1.5 (0.8)

10 (5.6)

1 (0.6) 25

200

ENABLE DSABLE

Page 29

Table 2 — LID Display Data (cont)

EXAMPLE 9 — SERVICE2 DISPLAY SCREEN

To access this display from the LID default screen:

1. Press MENU

2. Press SERVICE

3. Scroll down to highlight EQUIPMENT SERVICE.

4. Press SELECT

5. Scroll down to highlight SERVICE2.

6. Press SELECT

OPTIONS BOARD 1 20 mA POWER CONFIGURATION

External = 0, Internal = 1 RESET 20 mA Power Source 0,1 res 20 ma

DEMAND 20 mA Power Source 0,1 dem 20 ma 0 SPARE ALERT ENABLE

Disable = 0, 1 = High Alert, 2 = Low Alert, 3 = High Alarm, 4 = Low Alarm Temp = Alert Threshold

CHWS Temp Enable 0-4 chws en CHWS Temp Alert –40-245 (–40-118) DEG F (DEG C) chws al 245 (118) CHWR Temp Enable 0-4 chwr en 0 CHWR Temp Alert –40-245 (–40-118) DEG F (DEG C) chwr al Reset Temp Enable 0-4 rres en 0 Reset Temp Alert –40-245 (–40-118) DEG F (DEG C) rres al 245 (118) Spare Temp 1 Enable 0-4 spr1 en Spare Temp 1 Alert –40-245 (–40-118) DEG F (DEG C) spr1 al 245 (118) Spare Temp 2 Enable 0-4 spr2 en 0 Spare Temp 2 Alert –40-245 (–40-118) DEG F (DEG C) spr2 al Spare Temp 3 Enable 0-4 spr3 en 0 Spare Temp 3 Alert –40-245 (–40-118) DEG F (DEG C) spr3 al

OPTIONS BOARD 2 20 mA POWER CONFIGURATION

External = 0, Internal = 1 SPARE 1 20 mA Power Source 0,1 sp1 20 ma SPARE 2 20 mA Power Source 0,1 sp2 20 ma 0

SPARE ALERT ENABLE Disable = 0, 1 = High Alert, 2 = Low Alert, 3 = High Alarm, 4 = Low Alarm Temp = Alert Threshold

Spare Temp 4 Enable 0-4 spr4 en Spare Temp 4 Alert –40-245 (–40-118) DEG F (DEG C) spr4 al 245 (118) Spare Temp 5 Enable 0-4 spr5 en 0 Spare Temp 5 Alert –40-245 (–40-118) DEG F (DEG C) spr5 al Spare Temp 6 Enable 0-4 spr6 en 0 Spare Temp 6 Alert –40-245 (–40-118) DEG F (DEG C) spr6 al Spare Temp 7 Enable 0-4 spr7 en 0 Spare Temp 7 Alert –40-245 (–40-118) DEG F (DEG C) spr7 al 245 (118) Spare Temp 8 Enable 0-4 spr8 en Spare Temp 8 Alert –40-245 (–0-118) DEG F (DEG C) spr8 al 245 (118) Spare Temp 9 Enable 0-4 spr9 en 0 Spare Temp 9 Alert –40-245 (–40-118) DEG F (DEG C) spr9 al

NOTE: This screen provides the means to generate alert messages based on exceeding the ‘‘Temp’’threshold for each point listed. If the ‘‘Enable’’ is set to 1, a value above the ‘‘Temp’’ threshold generates an alert message. If the ‘‘Enable’’ is set to 2, a value below the ‘‘Temp Alert’’ threshold generates an alert message. If the ‘‘Enable’’ is set to 0, alert generation is disabled. If the ‘‘Enable’’ is set to 3, a value above the ‘‘Temp’’ threshold generates an alarm. If the ‘‘Enable’’ is set to 4, a value below the ‘‘Temp’’ threshold generates an alarm.

DESCRIPTION CONFIGURABLE RANGE UNITS REFERENCE POINT NAME DEFAULT VALUE

245 (118)

245 (118) 245 (118)

245 (118)

EXAMPLE 10 — SERVICE3 DISPLAY SCREEN

To access this display from the LID default screen:

1. Press MENU

2. Press SERVICE

3. Scroll down to highlight EQUIPMENT SERVICE.

4. Press SELECT

5. Scroll down to highlight SERVICE3.

DESCRIPTION CONFIGURABLE RANGE UNITS REFERENCE POINT NAME DEFAULT VALUE

Proportional Inc Band 2-10 gv inc Proportional Dec Band 2-10 gv de 6.0 Proportional ECW Gain 1-3 gv ecw 2.0

Guide Vane Travel Limit 30-100 % gv lim

6.5

Page 30

Table 2 — LID Display Data (cont)

EXAMPLE 11 — MAINTENANCE (MAINT01) DISPLAY SCREEN

To access this display from the LID default screen:

1. Press MENU

2. Press SERVICE

3. Scroll down to highlight CONTROL ALGORITHM STATUS.

4. Press SELECT

5. Scroll down to highlight MAINT01.

DESCRIPTION RANGE/STATUS UNITS REFERENCE POINT NAME

CAPACITY CONTROL Control Point 10-120 (–12.2-48.9) DEG F (DEG C) ctrlpt Leaving Chilled Water –40-245 (–40-118) DEG F (DEG C) LCW Entering Chilled Water –40-245 (–40-118) DEG F (DEG C) ECW Control Point Error –99-99 (–55-55) DEG F (DEG C) cperr ECW Delta T –99-99 (–55-55) DEG F (DEG C) ecwdt ECW Reset –99-99 (–55-55) DEG F (DEG C) ecwres LCW Reset –99-99 (–55-55) DEG F (DEG C) lcwres Total Error + Resets –99-99 (–55-55) DEG F (DEG C) error Guide Vane Delta –2-2 % gvd Target Guide Vane Pos 0-100 % GV TRG Actual Guide Vane Pos 0-100 % GV ACT

Proportional Inc Band 2-10 gv inc Proportional Dec Band 2-10 gv dec Proportional ECW Gain 1-3 gv ecw Water/Brine Deadband 0.5-2 (0.3-1.1) DEG F (DEG C) cwdb

NOTE: Overriding is not supported on this maintenance screen.Active overrides show the associated point in alert (*). Reference point names with capital letters can be read by CCN and Building Supervisor software.

EXAMPLE 12 — MAINTENANCE (MAINT02) DISPLAY SCREEN

To access this display from the LID default screen:

1. Press MENU

2. Press SERVICE

3. Scroll down to highlight CONTROL ALGORITHM STATUS.

4. Press SELECT

5. Scroll down to highlight MAINT02.

6. Press SELECT

OVERRIDE/ALERT STATUS MOTOR WINDING TEMP† –40-245 (–40-118) DEG F (DEG C) MTRW

Override Threshold 150-200 (66-93) DEG F (DEG C) mt over CONDENSER PRESSURE –6.7-420 (–42-2896) PSI (kPa) CRP Override Threshold 90-245 (621-1689) PSI (kPa) cp over EVAPORATOR REFRIG TEMP –40-245 (–40-118) DEG F (DEG C) ERT Override Threshold 2-45 (1-7.2) DEG F (DEG C) rt over DISCHARGE TEMPERATURE –40-245 (–40-118) DEG F (DEG C) CMPD Alert Threshold 125-200 (52-93) DEG F (DEG C) cd alert BEARING TEMPERATURE –40-245 (–40-118) DEG F (DEG C) MTRB Alert Threshold 175-185 (79-85) DEG F (DEG C) tb alert

†Information is applicable to hermetic machines (19EX) only. NOTE: Overriding is not supported on this maintenance screen.Active overrides show the associated point in alert (*). Reference point names with

capital letters can be read by CCN and Building Supervisor software.

DESCRIPTION RANGE/STATUS UNITS REFERENCE POINT NAME

Page 31

Table 2 — LID Display Data (cont)

EXAMPLE 13 — MAINTENANCE (MAINT03) DISPLAY SCREEN

To access this display from the LID default screen:

1. Press MENU

2. Press SERVICE

3. Scroll down to highlight CONTROL ALGORITHM STATUS.

4. Press SELECT

5. Scroll down to highlight MAINT03.

6. Press SELECT

SURGE/HGBP ACTIVE ? NO/YES Active Delta P 0-200 (0-1379) PSI (kPa) dp a

Active Delta T 0-200 (0-111) DEG F (DEG C) dt a Calculated Delta T 0-200 (0-111) DEG F (DEG C) dt c

Surge Protection Counts 0-12 spc

NOTE: Override is not supported on this maintenance screen. Only values with capital letter reference point names are variables available for read operation.

To access this display from the LID default screen:

1. Press MENU

2. Press SERVICE

3. Scroll down to highlight CONTROL ALGORITHM STATUS.

4. Press SELECT

5. Scroll down to highlight MAINT04.

6. Press SELECT

DESCRIPTION RANGE/STATUS UNITS REFERENCE POINT NAME

EXAMPLE 14 — MAINTENANCE (MAINT04) DISPLAY SCREEN

DESCRIPTION RANGE/STATUS UNITS REFERENCE POINT NAME

LEAD/LAG: Conﬁguration DISABLE,LEAD,LAG,STANDBY, INVALID leadlag Load Balance Option DISABLE/ENABLE loadbal

LAG Start Time 0-60 MIN lagstart LAG Stop Time 0-60 MIN lagstop Prestart Fault Time 0-30 MIN preﬂt Pulldown: Delta T/Min x.xx D DEGF(DDEG C) pull dt

LEAD CHILLER in Control No/Yes leadctrl LAG CHILLER: Mode Reset,Off,Local,CCN lagmode

STANDBY CHILLER: Mode Reset,Off,Local,CCN stdmode

NOTES:

1. Values on this screen cannot be ‘‘forced’’ (that is, changed by an operator, from the LID or from any other device [such as a CCN terminal]).

2. D = delta degrees.

Current Mode DISABLE,LEAD,LAG,STANDBY, CONFIG llmode

Satisﬁed? No/Yes pull sat

Run Status Timeout,Recycle,Startup,Ramping,Running Start/Stop Stop,Start,Retain lag s s

Recovery Start Request No/Yes lag rec

Run Status Timeout,Recycle,Startup,Ramping,Running

Recovery Start Request No/Yes std rec

Start/Stop Stop,Start,Retain std s s

Demand,Override,Shutdown,Abnormal,Pumpdown

lagstat

stdstat

Page 32

PIC System Functions

NOTE: In the rest of this manual, words not part of paragraph headings and printed in all capital letters can be viewed on the LID (e.g., LOCAL, CCN, RUNNING, ALARM, etc.). Words printed both in capital letters and italics can also be viewed on the LID and are parameters (CONTROL MODE, COOLING SETPOINT,OVERRIDE THRESHOLD, etc.) with associated values (e.g., modes, temperatures, pressures, percentages, on, off, etc.). Words printed in all capital letters and in a box represent softkeys on the LID control panel

(e.g., ENTER the information that can appear on the LID screens. Figures 11-17 give an overview of LID operation and menus.

CAPACITY CONTROL — The PIC controls the chiller capacity by modulating the inlet guide vanes in response to chilled water temperature changes away from the WATER/

BRINE CONTROL POINT. The WATER/BRINE CONTROL POINT may be changed by a CCN network device or is de-

termined when the PIC adds any active chilled water reset to the chilled water SET POINT. The PIC uses the PROPOR-

TIONAL INC (Increase) BAND, PROPORTIONAL DEC (Decrease) BAND, and the PROPORTIONAL ECW (Entering Chilled Water)GAIN to determine how quickly or slowly

to respond. WATER/BRINE CONTROL POINT may be viewed/ overridden from the STATUS menu, STATUS01 screen.

ENTERING CHILLED WATER CONTROL — If this option is enabled, the PIC uses the ENTERING CHILLED WA-

TER temperature to modulate the vanes instead of theLEAVING CHILLED WATER temperature. The ENTERING CHILLED WATER control option may be viewed/modiﬁed from the

CONFIG screen, accessed from the EQUIPMENT CONFIGURATION table.

DEADBAND — This is the tolerance on the chilled water/ brine temperature WATER/BRINE CONTROL POINT. If the water temperature goes outside the WATER/BRINE DEAD- BAND, the PIC opens or closes the guide vanes in response until it is within tolerance. The PIC may be conﬁgured with a 0.5° to 2° F (0.3° to 1.1° C) deadband. WATER/BRINE DEADBAND may be viewed or modiﬁed from the SERVICE1 screen, accessed from the EQUIPMENT SERVICE table.

For example, a 1° F (0.6° C) deadband setting controls the water temperature within ±0.5° F (0.3° C) of the control point. This may cause frequent guide vane movement if the chilled water load ﬂuctuates frequently. A value of 1° F (0.6° C) is the default setting.

PROPORTIONALBANDSAND GAIN — Proportional band is the rate at which the guide vane position is corrected in proportion to how far the chilled water/brine temperature is from the control point. Proportional gain determines how quickly the guide vanes react to how quickly the temperature is moving from WATER/BRINE CONTROL POINT. Pro- portional bands and gain values can be viewed/modiﬁed from the SER VICE3screen (accessed from the EQUIPMENT CONFIGURATION table) and the MAINT01 screen (accessed from the CONTROL ALGORITHM STATUS table).

The Proportional Band — There are two response modes, one for temperature response above the control point, the other for response below the control point.

The ﬁrst type is called PROPORTIONAL INC BAND, and it can slow or quicken vane response to chilled water/brine temperature above the WATER/BRINE DEADBAND.Itcan be adjusted from a setting of 2 to 10; the default setting is

6.5. PROPORTIONAL DEC BAND can slow or quicken vane response to chilled water temperature below deadband plus the control point. It can be adjusted on the LID from a setting of 2 to 10, and the default setting is 6.0. Increasing either of these settings causes the vanes to respond more slowly than at a lower setting.

and EXIT ). See Table 2 for examples of

The PROPORTIONAL ECW GAIN can be adjusted at the LID display from a setting of 1.0 to 3.0, with a default setting of

2.0. Increase this setting to increase guide vane response to a change in entering chilled water temperature.

DEMAND LIMITING — The PIC responds to the ACTIVE DEMAND LIMIT set point by limiting the opening of the guide vanes. It compares the set point to either COMPRES-

SOR MOTORLOADorCOMPRESSORMOTORLOADCURRENT (percentage), depending on how the control is con-

ﬁgured for the DEMAND LIMIT SOURCE which is accessed on the SERVICE1 screen. The default setting is current limiting. The ACTIVE DEMAND LIMIT may be viewed on the STATUS01 screen.

CHILLER TIMERS — The PIC maintains 2 runtime clocks, known as COMPRESSOR ONTIME and SERVICE ONTIME. COMPRESSOR ONTIME indicates the total lifetime compressor run hours. This timer can register up to 500,000 hours before the clock turns back to zero.The SERV- ICE ONTIME is a resettable timer that can be used to indicate the hours since the last service visit or any other event. The time can be changed from the LID to whatever value is desired. This timer can register up to 32,767 hours before it rolls over to zero.

The chiller also maintains a start-to-start timer and a stopto-start timer. These timers limit how soon the chiller can be started. See the Start-Up/Shutdown/Recycle Sequence section, page 43, for operational information.

OCCUPANCY SCHEDULE — The chiller schedule, described in the Time Schedule Operation section, page 18, determines when the chiller can run. Each schedule consists of 1 to 8 occupied/unoccupied time periods, set by the operator. These time periods can be enabled (or not enabled) on each day of the week and for holidays. The day begins with 0000 hours and ends with 2400 hours. The chiller is in an occupied state unless an unoccupied time period is in effect.

NOTE: To determine whether or not the chiller is in an occupied state and can be started, access the STATUS01 screen and scroll to the OCCUPIED? parameter. If the value in the right column is YES, the chiller is in an occupied state and can turn on or can be started. If the value is NO, the chiller is in an unoccupied state; that is, it can shut down or cannot be started without performing an override.

The schedules can be set to follow the building schedule or to be in an occupied state 100% of the time. The schedules also can be bypassed by forcing the CHILLER START/ STOP parameter on the STATUS01 screen to START. For more information on forced starts, see Local Start-Up, page 43. The schedules also can be overridden to keep the chiller in an occupied state for up to 4 hours, on a one-time basis.

NOTE: A parameter value can be 9forced9 (changed by an operator) from the LID screen or from another control device such as a CCN terminal. For example, if the CHILLER START/STOP parameter is set to START, the operator can go to the LID and change the value to STOP to 9force9 the chiller to stop.

Figure 14 shows a schedule for a typical office building time schedule, with a 3-hour,off-peak cool down period from midnight to 3 a.m., following a weekend shutdown. For example, holiday periods are set to be unoccupied 24 hours per day.The building operates Monday through Friday, 7:00 a.m. to 6:00 p.m., with a Saturday schedule of 6:00 a.m. to 1:00 p.m., and includes the Monday midnight to 3:00 a.m. weekend cool-down schedule.

Page 33

NOTE: This schedule is for illustration only, and is not intended to be a recommended schedule for chiller operation.

Depending on its operating mode, the chiller uses the fol-

lowing occupancy schedules:

• LOCAL mode — Occupancy Schedule 01(OCCPC01 on the SCHEDULE screen).

• ICE BUILD mode — Occupancy Schedule 02 (OCCPC02 on the SCHEDULE screen).

• CCN mode — Occupancy Schedule 03-99 (OCCPC02OCCPC99 on the SCHEDULE screen).

The CCN schedule number is speciﬁed on the CONFIG screen, which is accessed from the EQUIPMENT CONFIGURATION table. The schedule number can be any value from 03 to 99. If this schedule number is changed on the CONFIG screen, the operator must use the ATTACHTONETWORK DEVICE screen to upload the new number into the schedule screen. See Fig. 12.

Safety Controls — The PIC monitors all safety control

inputs, and if required, shuts down the chiller or limits the guide vanes to protect the chiller from possible damage from several conditions, including:

• high bearing temperature

• high motor winding temperature

• high discharge temperature

• low compressor oil pressure

• low gear oil pressure

• high gear oil temperature

• low cooler refrigerant temperature/pressure

• condenser high pressure or low pressure

• inadequate water/brine cooler and condenser ﬂow

• high, low, or loss of voltage

• excessive motor acceleration time

• excessive starter transition time

• lack of motor current signal

• excessive motor amps

• excessive compressor surge

• temperature and transducer faults

Starter faults or optional protective devices within the starter can shut down the chiller. These devices depend on what options have been purchased.

Default Screen Freeze — When the chiller is in an

alarm state, the default LID display freezes; that is, it stops updating. The ﬁrst line of the LID default screen displays a primary alarm message; the second line displays a secondary alarm message. The LID default screen freezes to allow the operator to see the condition of the chiller at the time of the alarm. Knowledge of the operating state of the chiller at the time an alarm occurs is useful when troubleshooting. Current chiller information can be viewed on the STATUS screens (see Table 2, Examples 1-4). Once all existing alarms are

cleared by pressing the RESET screen returns to normal operation.

softkey, the default LID

Auxiliary Compressor Oil Pump Control — The

compressor oil pump (optional) is controlled by the PIC. If, during start-up, the main oil pump cannot raise pressure to 18 psi (124 kPa), the auxiliary oil pump (optional) is energized. During compressor operation, the auxiliary oil pump is energized if the oil pressure falls below the alert threshold (18 psi [124 kPa]). Once the auxiliary compressor oil pump is running, it stays on until the compressor is turned off and is deenergized along with the main oil pump after the postlubrication period.

Auxiliary Gear Oil Pump Control — The optional

auxiliary gear oil pump is controlled by the PIC. During startup, if the main gear oil pump cannot raise the oil pressure at least 20 psi (139 kPa), the auxiliary gear oil pump is energized. If, after 30 seconds, the required oil pressure has not been established, the PIC initiates an alarm and does not allow the chiller to start. During operation, the auxiliary gear oil pump is energized if the oil pressure falls below the alert threshold (15 to 20 psi [103 to 139 kPa]). Once the auxiliary gear oil pump is running, it stays on until the compressor is turned off and is deenergized with the main gear oil pump after the post-lubrication period.

Shaft Seal Oil Control — For all open-drive chillers,

the shaft seal must be bathed in oil at all times, especially when the chiller is not running. This ensures that refrigerant will not leak past the seal. The PIC energizes the compressor oil pump for one minute if the oil pump has not operated during the past 12 hours.

If a compressor motor overload or ground fault occurs, check the motor for grounded or open phases before attempting a restart.

If the PIC control initiates a safety shutdown, the control displays a primary and secondary alarm message on the LID, energizes an alarm relay in the starter, and blinks the alarm light on the control panel. The alarm information is stored in memory and can be viewed on the LID by accessing the ALARM HISTORY table along with a troubleshooting message.

To give a more speciﬁc operating condition warning, the operator can also deﬁne alert limits on various monitored inputs. Safety contact and alert limits are deﬁned in Table 3. Alarm and alert messages are listed in the Troubleshooting Guide section, page 83.

SHUNT TRIP — The PIC can include an optional shunt trip function that acts as a safety trip. The shunt trip is wired from an output on the SMM to the motor circuit breaker. If the PIC tries to shut down the compressor using normal shutdown procedures but is unsuccessful for 30 seconds, the shunt trip output is energized and trips off the circuit breaker. If ground fault protection has been applied to the starter, the ground fault trip also energizes the shunt trip to trip the circuit breaker.

IMPORTANT: If control power is turned offfor more than 12 hours, the refrigerant charge must be pumped into the economizer/storage vessel. Because the oil heater is also turned off during this time, storing the refrigerant prevents refrigerant from migrating into the oil.

RampLoading Control — Ramp loading control slows

down the rate at which the compressor loads up. It prevents the compressor from loading up during the short time between chiller start-up and the time the chilled water loop has to be brought down to normal design conditions. Ramp loading helps to reduce electrical demand by slowly bringing the chilled water temperature to the control point temperature. The total power draw during this period stays almost unchanged.

The PIC bases ramp loading on either the chilled water temperature or on motor load. See the Table 2, Example 6 (CONFIG screen).

1. The temperature ramp loading rate is an operator-

conﬁgured value that limits the rate at which either the leaving chilled water or entering chilled water temperature decreases (TEMP PULLDOWN DEG/MIN parameter on the CONFIG screen). The lowest temperature ramp rate is used the ﬁrst time the chiller is started (at commissioning). The lowest temperature ramp rate is also used if chiller power has been off for 3 hours or more (even if the motor ramp load control method has been selected).

Page 34

Table 3 — Protective Safety Limits and Control Settings

MONITORED PARAMETER LIMIT APPLICABLE COMMENTS

TEMPERATURE SENSORS OUT OF RANGE

PRESSURE TRANSDUCERS OUT OF RANGE

COMPRESSOR DISCHARGE TEMPERATURE

BEARING TEMPERATURE .220 F (104.4 C) Preset, alert setting conﬁgurable EVAPORATOR REFRIGERANT

TEMPERATURE (Temp converted from Pressure Reading)

TRANSDUCER VOLTAGE ,4.5 vdc . 5.5 vdc

CONDENSER PRESSURE — SWITCH

COMPRESSOR OIL PRESSURE — SWITCH Cutout ,11 psid (76 kPad) ± 1.5 psid (10.3 kPad)

— CONTROL

LINE VOLTAGE — HIGH .110% for one minute

COMPRESSOR MOTOR LOAD (% Compressor Amps)

STARTER ACCELERATION TIME (Determined by inrush current going below 100% compressor motor load)

STARTER TRANSITION .75 seconds Reduced voltage starters only

CONDENSER FREEZE PROTECTION

IMPELLER CLEARANCE Displacement switch open Thrust movement excessive MOTOR LEAK DETECTOR (TEWAC

MOTORS ONLY) GEAR OIL TEMPERATURE

— CONTROL GEAR OIL PRESSURE

—CONTROL

— LOW ,90% for one minute or <85% for 3 seconds — SINGLE-CYCLE ,50% for one cycle

— CONTROL 215 psig (1482 kPa) Preset

–40 to 245 F (–40 to 118.3 C) Must be outside range for 2 seconds

0.08 to 0.98 Voltage Ratio

.220 F (104.4 C) Preset, alert setting conﬁgurable

,33 F (for water chilling) (0.6° C) ,Brine Refrigerant Trippoint (set point adjustable

from 0 to 40 F [–18 to 4 C] for brine chilling)

.218 ± 7 psig (1503 ± 48 kPa), reset at 120 ± 10 (827 ± 69 kPa)

Cut-in .16.5 psid (114 kPad) ± 4 psid (27.5 kPad) Cutout ,15 psid (103 kPad)

Alert ,18 psid (124 kPad)

.110% for 30 seconds Preset ,10% with compressor running Preset .10% with compressor off Preset

.45 seconds .10 seconds

Energizes condenser pump relay if condenser refrigerant temperature or condenser entering water temperature is below the conﬁgured condenser freeze point temperature. Deenergizes when the temperature is5F(3C)above condenser freeze point temperature.

Water from motor cooling is leaking Cut-Out > 150 F (66 C)

Alert > 130-145 (54 - 63 C) Cut-out < 12 psi (83 kPa)

Alert < 15-20 psi (103 - 139 kPa)

Must be outside range for 2 seconds. Ratio = Input Voltage ÷ Voltage Reference

Preset, conﬁgure chilled medium for water (Service1 table)

Conﬁgure chilled medium for brine (Service1 table). Adjust brine refrigerant trippoint for proper cutout

Preset (Read voltage at terminals 34 and 35 on PSIO module)

Preset

Preset, no calibration needed Preset Preset, based on transformed line voltage to

24 vac rated-input to the Starter Management Module. Also monitored at PSIO power input.

For chillers with reduced voltage mechanical and solid-state starters

For chillers with full voltage starters (Conﬁgured on Service1 table)

CONDENSER FREEZE POINT conﬁgured in Service01 table with a default setting of 34F(1C).

Water sensors are installed only on open-drive motors that use water cooling. (Totally enclosed, water-to-air cooled [TEWAC] motors)

Preset Adjustable

FLOW SWITCHES (Field Supplied)

Operate water pumps with chiller off. Manually reduce water ﬂow and observe switch for proper cutout. Safety shutdown occurs when cutout time exceeds 3 seconds.

CUT-OFF SETTING ADJUSTMENT SCREW

Carrier Part No. HK06ZC033

Carrier Part No. HK06ZC001

NOTE: Dimensions in parentheses are in millimeters.

Page 35

2. The motor load ramp loading rate is an operator-configured value that limits the rate at which the compressor motor current or compressor motor load increases. (LOAD PULL- DOWN %/MIN on the CONFIG screen).

To select the ramp type, highlight the SELECT RAMP TYPE parameter on the CONFIG screen and select either 0(TEMP)or1(LOAD). Motor load (1) is the default ramp loading control type.

Capacity Override (See Table4) — Capacity over-

rides can prevent some safety shutdowns caused by exceeding the motor amperage limit, refrigerant low temperature safety limit, motor high temperature safety limit, and condenser high pressure limit. In all of these cases, there are 2 stages of compressor vane control.

1. The guide vanes are kept from opening further, and the

status line on the LID displays the reason for the override.

2. The guide vanes are closed until the condition decreases

below the ﬁrst step set point. Then, the vanes are released to normal capacity control.

Whenever the motorcurrentdemandlimitsetpoint is reached, it activates a capacity override, again using the 2-step process. Exceeding 110% of the rated load amps for more than 30 seconds initiates a safety shutdown.

The compressor high lift (surge prevention) set point causes a capacity override as well. When the surge prevention set point is reached, the PIC normally prevents the guide vanes from opening. See the Surge Prevention Algorithm section, page 37. If the chiller is equipped with the hot gas bypass option, the PIC opens the hot gas bypass valve instead of holding the guide vanes.

HighDischarge TemperatureControl— If the dis-

charge temperature increases above 200 F (93 C), the guide vanes are proportionally opened to increase gas ﬂow through the compressor.If the leaving chilled water temperature drops 5° F (2.8° C) below the control point temperature, chiller enters the RECYCLE mode.

OilSump TemperatureControl— The oil sump tem-

perature control is regulated by the PIC which uses the oil heater relay when the chiller is shut down.

As part of the pre-start checks executed by the controls, the PIC compares the oil sump temperature to the evaporator refrigerant temperature. If the difference between these 2 temperatures is 50 F (27.8 C) or less, the start-up is delayed until the oil temperature difference is 50 F (27.8 C) or more. Once this temperature is conﬁrmed, the start-up continues.

The oil heater relay is energized whenever the chiller compressor is off and the oil sump temperature is less than 150 F (65.6 C) or the oil sump temperature is less than the cooler refrigerant temperature plus 70° F (39° C). The oil heater is turned off when the oil sump temperature is either

• more than 160 F (71.1 C)

• or the oil sump temperature is more than 155 F (68.3 C)

and more than the cooler refrigerant temperature plus 75° F (41.6° C).

The oil heater is always off during start-up or when the compressor is running.

When a power failure to the PSIO module has occurred for more than 3 hours (i.e., initial start-up), the compressor guide vane opening is slowed down to prevent excessive oil foaming that may result from refrigerant migration into the oil sump during the power failure. The vane opening is slowed via temperature ramp loading to a value of 2° F (1.1° C) per minute.

OVERRIDE CAPACITY

CONTROL

HIGH CONDENSER

PRESSURE

LOW REFRIGERANT

TEMPERATURE

(Refrigerant Override

Delta Temperature)

HIGH COMPRESSOR

LIFT

(Surge Prevention)

MANUAL

GUIDE VANE

TARGET

MOTOR LOAD —

ACTIVE

DEMAND LIMIT

LEGEND

HGBP — High Gas Bypass P1 — Minimum Pressure Load P2 — Maximum Pressure Load T1 — Minimum Temperature Load T2 — Maximum Temperature Load

View/Modify

on LID Screen

Equipment

Algorithm

Table 4 — Capacity Overrides

FIRST STAGE SETPOINT

Default Value Conﬁgurable Range Value Value

Service1

Control Maint01

Status01 100% 40 to 100%

125 psig

(862 kPa)

,3° F (1.6° C)

(Above Trippoint)

Min: T1 — 1.5° F

(0.8° C) P1 — 50 psid (345 kPad)

Max: T2 — 10° F

(5.6° C) P2 — 85 psid (586 kPad)

Automatic 0 to 100% None

90 to 200 psig

(620 to 1379 kPa)

2° to 5° F

(1° to 3° C)

0.5° to 15° F

(0.3° to 8.3° C)

30 to 170 psid

(207 to1172 kPad)

0.5° to 15° F

(0.3° to 8.3° C)

30 to 170 psid

(207 to 1172 kPad)

SECOND STAGE

SETPOINT

.Override

Set Point

+ 4 psid (28 kPad)

<Trippoint + Override

DT –1° F (0.56° C)

None

>5% of

Set Point

OVERRIDE

TERMINATION

,Override

Set Point

.Trippoint + Override

DT +2° F

(1.2° C)

Within

Lift Limits

Plus Surge/

HGBP

Deadband

Setting

Release of

Manual Control

2% Lower

Than

Set Point

Page 36

Oil Cooler — The oil for the external gear and the com-

pressor must be cooled while the compressor is running. The compressor oil cooler is a water-cooled, helical, tube-inshell type heat exchanger. A plug valve is manually set to maintain proper temperatures. Set the valve to maintain a 145 F (63 C) oil sump temperature while the compressor is running.

The gear oil cooler is a water-cooled, helical tube-in-shell type heat exchanger. A plug valve is manually set to maintain proper temperatures. Set the valve to maintain the oil temperature leaving the cooler at 130 F (54 C) while the compressor is running.

RemoteStart/Stop Controls — A remote device, such

as a time clock with a set of contacts, may be used to start and stop the chiller. However, the device should not be programmed to start and stop the chiller more than 2 or 3 times every 12 hours. If more than 8 starts in 12 hours occur, the Excessive Starts alarm is displayed, and the chiller is prevented from starting. The operator must reset the alarm at the LID in order to override the starts counter and start the chiller. If the automatic restart after a power failure (AUTO REST ARTOPTION ) is not activated (disabled) when a power failure occurs and the remote contact is closed, the PIC control activates an alarm because of the loss of voltage.

The contacts for remote starting are wired into the starter at terminal strip TB5, terminals 8A and 8B. See the certiﬁed drawings for further details on contact ratings. The contacts must be dry (no power).

Spare Safety Inputs — Normally closed (NC) digital

inputs for additional ﬁeld-supplied safeties may be wired to the spare protective limits input channel in place of the factoryinstalled jumper. (Wire multiple inputs in series.) Opening any contact results in a safety shutdown and LID display. Refer to the certiﬁed drawings for safety contact ratings.

Analog temperature sensors may also be added to the options modules, if installed. These may be programmed to activate an alert on the CCN network, but not shut down the chiller.

SpareAlarmContacts — Twospare sets of alarm con-

tacts are provided in the starter. The contact ratings are provided in the certiﬁed drawings. The contacts are located on terminal strip TB6, terminals 5A and 5B, and terminals 5C and 5D.

Condenser Pump Control — The chiller monitors

the condenser pressure (CONDENSER PRESSURE parameter on the STATUS01 screen) and may turn on the condenser pump if the pressure becomes too high whenever the compressor is shut down. The condenser pressure override (COND PRESSURE OVERRIDE parameter on the SERVICE1 screen) is the value that determines this pressure point. Its default value is 125 psi (862 kPa). If the condenser pressure is greater than or equal to the condenser pressure override, and the entering condenser water temperature (EN- TERING CONDENSER WATER parameter on the STATUS01 screen) is less than 115 F (46 C), then the condenser pump energizes to try to decrease the pressure. The pump turns offwhen the condenser pressure is 5psi (34 kPa) less than the pressure override, or when the condenser refrigerant temperature (CONDENSER REFRIG TEMP on the STATUS01 screen) is within 3° F (2° C) of the entering condenser water temperature.

Condenser Freeze Prevention — This control al-

gorithm helps prevent condenser tube freeze-up by energizing the condenser pump relay. If the pump is controlled by the PIC, starting the pump helps prevent the water in the condenser from freezing. Condenser freeze prevention can occur whenever the chiller is not running except when it is either actively in pumpdown or in pumpdown lockout with the freeze prevention disabled.

When the condenser refrigerant temperature is less than or equal to the condenser freeze point (CONDENSER FREEZE POINT on the SERVICE1 screen), or the entering condenser water temperature is less than or equal to the condenser freeze point, then the condenser water pump (CONDENSER WA- TER PUMP on the STATUS02 screen) is energized until the condenser refrigerant temperature is greater than the condenser freeze point plus 5° F (2.7° C). If the chiller is in PUMPDOWN mode and the pump is energized, the PIC activates an alarm. If the chiller is not in PUMPDOWN mode and the pump is energized, the PIC activates an alert. If the chiller is in RECYCLE shutdown mode, the mode transitions to SHUTDOWN (non-recycle shutdown).

Tower-Fan Relay — This control can be used to assist

the condenser water temperature control system (ﬁeld supplied). Low condenser water temperature can cause the chiller to shut down on low refrigerant temperature. The tower fan relay, located in the starter, is controlled by the PIC to energize and deenergize as the pressure differential between cooler and condenser vessels changes. This function prevents low condenser water temperature and maximizes chiller efficiency. The tower-fan relay can only accomplish this if the relay has been added to the cooling tower temperature controller.The tower-fan relay (TOWER FAN RELAY on the STATUS02 screen) is turned on whenever the condenser water pump is running, ﬂow is veriﬁed, and the difference between cooler and condenser pressure is more than 30 psid (207 kPad) or entering condenser water temperature is greater than 85 F (29 C). The tower-fan relay is deenergized whenever the condenser pump is off, ﬂow is lost, the evaporator refrigerant temperature is less than the override temperature, or the differential pressure is less than 28 psid (193 kPad) and entering condensing water is less than 80 F (27 C).

IMPORTANT:A ﬁeld-supplied water temperature control system for condenser water should be installed. The system should maintain the leaving condenser water temperature at 20° F (11° C) above the leaving chilled water temperature.

The tower-fan relay control is not a substitute for a condenser water temperature control. When used with a water temperature control system, the tower-fan relay control can be used to help prevent low condenser water temperatures and associated problems.

Auto. Restart After Power Failure — This option,

which may be viewed or modiﬁed on the CONFIG screen (the AUTO RESTART OPTION parameter), can be enabled or disabled. If this option is enabled, the chiller starts up automatically after a single cycle dropout; low, high, or no voltage; and the power is within ±10% of normal. The 15-minute start-to-start timer and the stop-to-start timer are ignored during this type of start-up.

When power is restored after a power failure, and if the compressor had been running, the oil pump is energized for one minute before the evaporator pump is energized. The Auto. Restart function then continues like a normal start-up.

Page 37

Water/Brine Reset — Three types of chilled water/

brine reset are available, Reset Type 1, Reset Type 2, and Reset Type 3. They can be viewed or modiﬁed on the CONFIG screen (accessed from the EQUIPMENT CONFIGURATION table). See Table 2, Example 6.

The LID default screen status message indicates when a reset is active. The WATER/BRINE CONTROL POINT tem- perature on the STATUS01 table indicates the chiller’s current reset temperature.

To conﬁgure a reset type, input all conﬁguration information for that reset type on the CONFIG screen. Then activate the reset type by entering the reset type number in the SELECT/ ENABLE RESET TYPE input line.

RESET TYPE 1 (Requires an optional 8-input module) — Reset Type 1 is an automatic chilled water temperature reset based ona4to20mAinput signal. The value for Rest Type 1 is user conﬁgurable (DEGREES RESET AT 20 mA). It is a temperature that corresponds to a 20 mA signal. (4 mA corresponds to 0° F [0° C]; 20 mA corresponds to the temperature entered by the operator.)

This reset type permits up to ±30° F (±16° C) of automatic reset to the chilled water/brine temperature set point, based on the input froma4to20mAsignal. The signal is hardwired into the No. 1 eight-input module.

If the 4 to 20 mA signal is externally powered from the 8-input module, the signal is wired to terminals J1-5(+) and J1-6(–). If the signal is powered internally by the 8-input module (for example, when using variable resistance), the signal is wired to J1-7(+) and J1-6(–). The PIC must be conﬁgured on the SERVICE2 screen to ensure that the appropriate power source is identiﬁed. See Table 2, Example 9, 20 mA POWER CONFIGURATION.

RESET TYPE 2 (Requires an optional 8-input module) — Reset Type 2 is an automatic chilled water temperature reset based on a remote temperature sensor input.

This reset type permits ±30° F (±16° C) of automatic reset to the set point based on a temperature sensor wired to the No. 1 eight-input module (see wiring diagrams or certiﬁed drawings). The temperature sensor must be wired to terminal J1-19 and J1-20.

Conﬁgure Reset Type 2 on the CONFIG screen (Table 2, Example 6). Enter the temperature of the remote sensor at the point where no temperature reset will occur (REMOTE TEMP [NO RESET]). Next, enter the temperature at which the full amount of reset will occur (REMOTE TEMP [FULL RESET]). Then, enter the maximum amount of reset required to operate the chiller (DEGREES RESET). Reset Type 2 can now be activated.

RESET TYPE 3 — Reset Type 3 is an automatic chilled water temperature reset based on cooler temperature difference. This reset adds ±30° F (±16° C) based on the temperature difference between entering and leaving chilled water. Reset Type 3 is the only reset available without the need for a No. 1 eight-input module. No wiring is required for Reset Type 3, because it already uses the cooler water sensors.

Conﬁgure Reset Type 3 on the CONFIG screen (Table 2, Example 6). Enter the chilled water temperature difference (the difference between entering and leaving chilled water) at which no temperature reset occurs (CHW DELTA T [NO RESET]). This chilled water temperature difference is usually the full design load temperature difference. Enter the difference in chilled water temperature at which the full amount of reset occurs (CHW DELTA T [FULL RESET]). Next, enter the amount of reset (DEGREES RESET). Reset Type 3 can now be activated.

Demand Limit Control Option (Requires Optional 8-Input Module) —

be externally controlled witha4to20mAsignal from an Energy Management System (EMS). The option (20 mA DE- MAND LIMIT OPTION) is enabled or disabled on the CONFIG screen (Table 2, Example 6). When enabled, the control is set for 100% demand with 4 mA and an operator conﬁgured minimum demand set point at 20 mA (DEMAND LIMIT AT 20 mA).

The EMS demand reset input is hardwired into the No. 1 8-input module. The signal may be internally powered by the module or externally powered. If the signal is externally powered, the signal is wired to terminals J1-1(+) and J1-2(–). If the signal is internally powered, the signal is wired to terminals J1-3(+) and J1-2(–). When enabled, the control is set for 100% demand with 4 mA and an operator conﬁgured minimum demand set point at 20 mA (DEMAND LIMIT

AT 20 mA).

The demand limit may

Surge Prevention Algorithm — Surge occurs when

lift conditions become so high that the gas ﬂow across the impeller reverses. This condition can eventually cause chiller damage. Lift is deﬁned as the difference between the pressure at the impeller eye and the impeller discharge. The maximum lift that a particular impeller wheel can produce varies with the gas ﬂow across the impeller and the size of the wheel.

The surge prevention algorithm is operator conﬁgurable and can determine if lift conditions are too high for the compressor. If they are, the PIC takes corrective action. The algorithm also notiﬁes the operator, via the LID, that chiller operating conditions are marginal.

The surge prevention algorithm ﬁrst determines if corrective action is necessary. This is done by checking 2 sets of operator conﬁgured data points: the minimum load points (MIN. LOAD POINTS [T1/P1]) and the maximum load points (FULL LOAD POINTS [T2/P2]). See the SERVICE1 screen or Table 2, Example 8. These points have default settings. Information on how to modiﬁy the default minimum and maximum load points can be found in the Input Service Conﬁgurations section on page 54.

Figures 18 and 19 graphically display these settings and the algorithm function. The 2 sets of load points (default settings) describe a line that the algorithm uses to determine the maximum lift of the compressor. Whenever the actual differential pressure between the cooler and condenser and the temperature difference between the entering and leaving chilled water are above the line on the graph (as deﬁned by the minimum and maximum load points) the algorithm goes into a corrective action mode. If the actual values are below the line, the algorithm takes no action.

Corrective action can be taken by making one of 2 choices. If the optional hot gas bypass line is present, and the operator selects the hot gas bypass option on the SERVICE1 screen (selects 1 for the SURGE LIMIT/HGBP OPTION), then the hot gas bypass valve can be energized. If the hot gas bypass option is not present, then the SURGE LIMIT/HGBP OPTION is on the default setting (0), and the guide vanes are held. (Also see Table 4, Capacity Overrides.) Both corrective actions reduce the lift experienced by the compressor and help to prevent a surge condition.

Page 38

DP = (Condenser psi) − (Cooler psi) DT = (ECW) − (LCW)

ECW — Entering Chilled Water HGBP — Hot Gas Bypass LCW — Leaving Chilled Water

LEGEND

Fig. 18 — 17EX Hot Gas Bypass/Surge

Prevention With Default Settings (English)

parameter, Table 2, Example 13) can be monitored on the MAINT03 screen. The SURGE TIME PERIOD parameter is displayed and conﬁgured on the SERVICE1 screen. See Table 2, Example 8. It has a default of 2 minutes.

Lead/Lag Control — Lead/lag is a control system pro-

cess that automatically starts and stops a lag or second chiller in a 2-chiller system. Refer to Fig. 15 and 16 for menu, table, and screen selection information. On chillers that have PSIO software with lead/lag capability, it is possible to use the PIC controls to perform the lead/lag function on 2 chillers.A third chiller can be added to the lead/lag system as a standby chiller to start up if the lead or lag chiller in the system has shut down during an alarm condition and additional cooling is required.

NOTE: Lead/lag parameters can be viewed and modiﬁed on the LEAD/LAG CONFIGURATION screen, accessed from the EQUIPMENT CONFIGURATION table. See Table 2, Example 7. Lead/lag status during chiller operation is viewed on the MAINT04 screen, accessed from the CONTROL ALGORITHM STATUS table. See Table 2, Example 14.

Lead/Lag System Requirements:

• all chillers must have PSIO software capable of performing the lead/lag function

• water pumps MUST be energized from the PIC controls

• water ﬂows should be constant

• CCN Time Schedules for all chillers must be identical

Operation Features:

• 2 chiller lead/lag

• addition of a third chiller for backup

• manual rotation of lead chiller

• load balancing if conﬁgured

• staggered restart of the chillers after a power failure

• chillers may be piped in parallel or in series chilled water ﬂow

DP = (Condenser kPa) − (Cooler kPa) DT = (ECW) − (LCW)

ECW — Entering Chilled Water HGBP — Hot Gas Bypass LCW — Leaving Chilled Water

LEGEND

Fig. 19 — 17EX Hot Gas Bypass/Surge Prevention

With Default Settings (SI)

Surge Protection — Compressor surge can be de-

tected by the PIC based on operator conﬁgured settings. Surge causes amperage ﬂuctuations of the compressor motor. The PIC monitors these amperage swings, and if the swing is greater than the conﬁgured setting (SURGE DELTA PERCENT AMPS) in one second, then one surge event has occurred. The setting is displayed and conﬁgured on the SERVICE1 screen. Its default setting is 25% amps.

Asurge protection chiller shutdown occurs when the surge protection counter reaches 12 within an operator speciﬁed time period, known as the surge time period. The surge protection count (SURGE PROTECTION COUNTS

COMMON POINT SENSOR INSTALLATION — Lead/ lag operation does not require a common chilled water point sensor. Common point sensors can be added to the 8-input option module, if desired. Refer to the certiﬁed drawings for termination of sensor leads.

NOTE: If the common point sensor option is chosen on a chilled water system, each chiller should have its own 8-input option module and common point sensor installed. A chiller uses its own common point sensor forcontrol when that chiller is designated as the lead chiller. The PIC cannot read the value of common point sensors installed on other chillers in the chilled water system.

When installing chillers in series, use a common point sensor.If a common point sensor is not used, the leaving chilled water sensor of the upstream chiller must be moved into the leaving chilled water pipe of the downstream chiller.

If return chilled water control is required on chillers piped in series, the common point return chilled water sensor should be installed. If this sensor is not installed, the return chilled water sensor of the downstream chiller must be relocated to the return chilled water pipe of the upstream chiller.

To properly control the common supply point temperature sensor when chillers are piped in parallel, the water ﬂow through the shutdown chiller(s) must be isolated so there is no water bypass around the operating chiller. The common point sensor option must not be used if water bypass around the operating chiller is occurring.

CHILLER COMMUNICATION WIRING — Refer to the chiller Installation Instructions and the Carrier Comfort Network Interface section on page 53 of this manual for information on chiller communication wiring.

Page 39

LEAD/LAG OPERATION — The PIC control has the capability to operate 2 chillers in the lead/lag mode. It also has the additional capability to start a designated standby chiller when either the lead or lag chiller is not operating and capacity requirements are not being met. The lead/lag option operates in CCN mode only. If any other chiller conﬁgured for lead/lag is set to the LOCAL or OFF modes, it will be unavailable for lead/lag operation.

NOTE: Lead/lag conﬁguration is viewed and edited on the LEAD/LAG screen, accessed from the EQUIPMENT CONFIGURATION table of the SERVICE menu. See Table 2, Example 7. Lead/lag status during chiller operation is viewed on the MAINT04 screen, accessed from the CONTROL ALGORITHM STATUS table. See Table 2, Example 14.

Lead/Lag Chiller Conﬁguration and Operation — A chiller is designated the lead chiller when the LEAD/LAG SELECT parameter for that chiller is set to 1 on the LEAD/ LAG CONFIGURATION screen.Achiller is designated the lag chiller when the LEAD/LAD SELECT parameter for that chiller is set to 2. A chiller is designated the standby chiller when the LEAD/LAG SELECT parameter for that chiller is set to 3. Setting the LEAD/LAG SELECT parameter to 0 disables the lead/lag function in that chiller.

To conﬁgure the LAG ADDRESS parameter on the LEAD/ LAG CONFIGURATION screen, always use the address of the other chiller on the system. Using this address makes it easier to rotate the lead and lag chillers.

If improper address assignments are entered for the LAG ADDRESS and STANDBY ADDRESS parameters, the lead/lag is disabled and an alert (!) message displays on the LID. For example, if the lag chiller’s address matches the lead chiller’s address, the lead/lag function is disabled and an alert (!) message displays. The lead/lag maintenance screen (MAINT04) displays the message INVALID CONFIG in the LEAD/LAG CONFIGURATIONand CURRENTMODEﬁelds.

The lead chiller responds to normal start/stop controls such as occupancy schedule, forced start/stop, and remote start contact inputs. After completing start-up and ramp loading, the PIC evaluates the need for additional capacity. If additional capacity is needed, the PIC initiates the start-up of the chiller conﬁgured at the lag address. If the lag chiller is faulted (in alarm) or is in the OFF or LOCAL modes, then the chiller at the standby address (if conﬁgured) is requested to start. After the second chiller is started and is running, the lead chiller monitors conditions and evaluates whether the capacity has been reduced enough for the lead chiller to sustain the system alone. If the capacity is reduced enough for the lead chiller to sustain the control point temperatures alone, then the operating lag chiller is stopped.

If the lead chiller is stopped in CCN mode for any reason other than an alarm (*) condition, then the lag and standby chillers are stopped. If the conﬁgured lead chiller stops for an alarm condition, then the conﬁgured lag chiller takes the lead chiller’s place as the lead chiller and the standby chiller serves as the lag chiller.

If the conﬁgured lead chiller does not complete the start-up before the PRESTART FAULT TIMER (a user conﬁgured pa- rameter on the LEAD/LAG screen) elapses, then the lag chiller is started and the lead chiller shuts down. The lead chiller then monitors the request to start from the acting lead chiller. The pre-start fault timer is initiated at the time of a start request. This timer’s function is to provide a time-out if there is a pre-start alert condition that prevents the chiller from starting in a timely manner.

If the lag chiller does not achieve start-up before the pre-start fault time elapses, then the lag chiller is stopped and the standby chiller is requested to start, if conﬁgured and ready.

Standby Chiller Conﬁguration and Operation — The conﬁgured standby chiller is identiﬁed as such by having its LEAD/ LAG SELECT parameter assigned a value of 3. The standby chiller can only operate as a replacement for the lag chiller if one of the other two chillers is in an alarm (*) condition (as indicated on the LID panel). If both lead and lag chillers are in an alarm (*) condition, the standby chiller defaults to operate in CCN mode based on its conﬁgured occupancy schedule and remote contacts input.

Lag Chiller Start-Up Requirements — Before the lag chiller can be started, the following conditions must be met.

1. Lead chiller ramp loading must be completed.

2. Lead chiller’s chilled water temperature must be greater than the WATER/BRINECONTROL POINT (STATUS01 screen) plus half the WATER/BRINE DEAD- BAND (SERVICE1 screen).

NOTE: The chilled water temperature sensor may be the leaving chilled water sensor, the return water sensor, the common supply water sensor, or the common return water sensor, depending on which options are conﬁgured and enabled.

3. Lead chiller ACTIVE DEMAND LIMIT (STATUS01 screen) value must be greater than 95% of full load amps.

4. Lead chiller temperature pulldown rate (TEMP PULL- DOWN DEG/MIN on the CONFIG screen) of the chilled water temperature is less than 0.5° F (0.27° C) per minute.

5. The lag chiller status indicates it is in CCN mode and is not faulted. If the current lag chiller is in an alarm condition, then the standby chiller becomes the active lag chiller, if it is conﬁgured and available.

6. The conﬁgured time for the LAG START TIMER parameter has elapsed. The lag start timer starts when the lead chiller ramp loading is completed. The LAG STARTTIMER parameter is on the LEAD/LAG screen, which is accessed from the EQUIPMENT CONFIGURATION table. See Table 2, Example 7.

When all the above requirements have been met, the lag chiller is forced to a STARTUPmode. The PIC control then monitors the lag chiller for a successful start. If the lag chiller fails to start, the standby chiller, if conﬁgured, is started.

Lag Chiller Shutdown Requirements — The following conditions must be met in order for the lag chiller to be stopped.

1. Lead chiller COMPRESSOR MOTOR LOAD (STA-

TUS01 screen) value is less than the lead chiller percent capacity plus 15%. See STATUS01 screen or Table 2, Example 1.

NOTE: Lead chiller percent capacity = 100 – LAG PER-

CENT CAPACITY.

The LAG PERCENT CAPACITY value is conﬁgured on the LEAD/LAG CONFIGURATION screen.

2. The lead chiller chilled water temperature is less than

the WATER/BRINE CONTROL POINT plus 1/2 of the

W ATER/BRINE DEADBAND. The WATER/BRINE DEADBAND parameter is on the SERVICE1 screen. See

Table 2, Example 8.

3. The conﬁgured lag stop time (LAG STOP TIMER param-

eter on the LEAD/LAG CONFIGURATION screen) has elapsed. The lag start time starts when the LEAVING

CHILLED WATER temperature is less than the WATER/ BRINE CONTROL POINT plus 1/2 of the WATER/ BRINE DEADBAND, and the lead chiller COMPRESSOR MOTOR LOAD is less than the lead chiller percent ca-

pacity plus 15%. The lag stop timer is ignored if the chilled water temperature reaches 3° F (1.67° C) below the WA TER/

BRINE CONTROL POINT and the lead chiller COMPRESSOR MOTOR LOAD value is less than the lead chiller

percent capacity plus 15%.

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FAULTED CHILLER OPERATION — If the lead chiller shuts down because of an alarm (*) condition, it stops communicating with the lag and standby chillers. After 30 seconds, the lag chiller becomes the acting lead chiller and starts and stops the standby chiller, if necessary.

If the lag chiller faults when the lead chiller is also faulted, the standby chiller reverts to a stand-alone CCN mode of operation.

If the lead chiller is in an alarm (*) condition (indicated on the LID ), the RESET alarm, and the lead chiller is placed in CCN mode, the lead

chiller communicates and monitors the run status of the lag and standby chillers. If both the lag and standby chillers are running, the lead chiller does not attempt to start and does not assume the role of lead chiller until either the lag or standby chiller shuts down. If only one chiller is running, the lead chiller waits for a start request from the operating chiller. When the conﬁgured lead chiller starts, it assumes its role of lead chiller.

LOAD BALANCING — When the LOAD BALANCE OP- TION (LEAD/LAG screen) is enabled, the lead chiller sets the ACTIVE DEMAND LIMIT in the lag chiller to the lead chiller’s COMPRESSOR MOTOR LOAD value. This value has limits of 40% to 100%. When setting the lag chiller AC- TIVE DEMAND LIMIT ,the WATER/BRINECONTROL POINT is modiﬁed to a value of 3° F (1.67° C) less than the lead chiller’sW ATER/BRINECONTROLPOINT value. If the LOAD BALANCE OPTION is disabled, the ACTIVE DEMAND LIMIT and the WATER/BRINE CONTROL POINT are forced to the same value as the lead chiller.

AUTO. RESTART AFTER POWER FAILURE— When an auto. restart condition occurs, each chiller may have a delay added to the start-up sequence, depending on its lead/lag conﬁguration. The lead chiller does not have a delay. The lag chiller has a 45-second delay. The standby chiller has a 90-second delay. The delay time is added after the chiller water ﬂow veriﬁcation. The PIC controls ensure that the guide vanes are closed.After the guide vane position is conﬁrmed, the delay for lag and standby chillers occurs before energizing the oil pump. The normal start-up sequence then continues. The auto. restart delay sequence occurs whether the chiller is in CCN or LOCAL mode and is intended to stagger the compressor motor start-up times. This helps reduce the in-rush of demand on the building power system.

softkey is pressed to clear the

Ice Build Control — Ice build control automatically sets

the chilled WATER/BRINE CONTROL POINT of the chiller from a normal operation set point temperature to a temperature that allows an ice building operation for thermal storage.

NOTE: For ice build control to operate properly, the PIC controls must be placed in CCN mode.

The PIC can be conﬁgured for ice build operation by chang-

ing entries on the:

• CONFIG screen, accessed from the SERVICE menu

• OCCPC02S screen (ice build time schedule), accessed from

the SCHEDULE menu

• SETPOINT screen, accessed from the SETPOINT menu. Figures 15 and 16 show how to access each screen.

The ice build time schedule deﬁnes the periods during which the ice build option can be activated, if the ice build option is enabled. If the ice build time schedule overlaps other schedules, the ice build time schedule takes priority. During an ice

build period, the WATER/BRINE CONTROL POINT is set to the ICE BUILD SETPOINT (SETPOINT screen) for temperature control.

The ICE BUILD RECYCLE OPTION and ICE BUILD TERMINATION parameters are on the CONFIG screen. The ice build recycle option can be enabled or disabled from this screen; the ice build termination value can be set to 0, 1, or 2, depending on the factor that determines termination (temperature, contacts, or both). Ice build termination can occur when:

• the ENTERING CHILLED WATERtemperature is less than

the ICE BUILD SETPOINT

• the REMOTE CONTACTS INPUT (STATUS01 screen) is

opened based on input from an ice level indicator

• the end of the ice build time schedule has been reached. ICE BUILD INITIATION — The ice build option is acti-

vated via the ice build time schedule on the OCCPC02S screen. If the current time is set asan ice build time on the OCCPC02S screen and the ICE BUILD OPTION on the CONFIG screen is enabled, then the ice build option is active and the following events automatically take place (unless overridden by a higher authority CCN device):

1. CHILLER START/STOP is forced to START.

2. The WATER/BRINE CONTROL POINT is forced to the

ICE BUILD SETPOINT.

3. Any force (Auto) on the ACTIVE DEMAND LIMIT is

removed.

NOTE: Items 1-3 (shown above) do not occur if the chiller is conﬁgured and operating as a lag or standby chiller for lead/lag operation and is actively controlled by a lead chiller. The lead chiller communicates the ICE BUILD SETPOINT, desired CHILLER START/STOP state, and ACTIVE DE- MAND LIMIT to the lag or standby chiller as required for ice build, if conﬁgured to do so.

START-UP/RECYCLE OPERATION — If the chiller is not running when ice build activates, then the PIC checks the following parameters, based on the ICE BUILD TERMINATION value, to avoid starting the compressor unnecessarily:

• if the ICE BUILD TERMINATION parameter is set to 0

(temperature only), and the ENTERING CHILLED WA-

TER temperature is less than or equal to the ICE BUILD SETPOINT;

• if the ICE BUILD TERMINATION parameter is set to 1

(contacts only) and the remote contacts are open;

• if the ICE BUILD TERMINATION parameter is set to 3

(both temperature and contacts), the ENTERING CHILLED

W ATER temperature is less than or equal to the ICE BUILD SETPOINT, and the remote contacts are open.

The ICE BUILD RECYCLE OPTION determines whether or not the PIC goes into aRECYCLE mode. If the ICE BUILD RECYCLE OPTION is set to DSABLE (disable) when the ice build terminates, the PIC reverts to normal temperature control duty. If the ICE BUILD RECYCLE OPTION is set to ENABLE, when ice build terminates, the PIC goes into an ice build recycle mode and the chilled water pump relay remains energized to keep the chilled water ﬂowing. If the EN- TERING CHILLED W A TER(brine) temperature increases above the ICE BUILD SETPOINT plus the RECYCLE RESTART DELTATvalue, the compressor restarts and controls the chilled water/brine temperature to the ICE BUILD SETPOINT.

Page 41

TEMPERATURE CONTROL DURING ICE BUILD —During ice build, the capacity control algorithm uses the WATER/BRINE CONTROL POINT minus 5 F (2.7 C) to control the LEAVING CHILLED WATERtemperature. The ECW

CONTROL OPTION (see CONFIG screen), the 20 mA DEMAND LIMIT, and any temperature reset option are ig-

nored during ice build. TERMINATION OF ICE BUILD — Ice build termination

occurs under the following conditions:

1. Ice Build Time Schedule — The ice build function terminates when the current time is not designated as an ice build time period.

2. Entering Chilled Water Temperature — Compressor operation terminates based on temperature if the ICE BUILD TERMINATION parameter on the CONFIG screen is set to 0 (temperature only) and the ENTERING CHILLED

WATER temperature is less than the ICE BUILD SETPOINT.IftheICE BUILD RECYCLE OPTION is set to

ENABLE, a recycle shutdown occurs and recycle startup is based on a LEAVING CHILLED WATER tempera- ture greater than the WATER/BRINE CONTROL POINT plus RECYCLE RESTART DELTA T (see SERVICE1 screen).

3. Remote Contacts/Ice Level Input — Compressor operation terminates when the ICE BUILD TERMINATION parameter is set to 1 (contacts only) and the remote contacts are open. In this case, the contacts are used for ice level termination control. The remote contacts can still be opened and closed to start and stop the chiller if the current time is not a time designated as an ice build period. If the current time is designated as an ice build period, the contacts are used to stop the ice build function.

4. Entering Chilled Water Temperature and Remote Contacts — Compressor operation terminates when the ICE BUILD TERMINATION parameter is set to 2 (both temperature and contacts) and the previously described conditions for ENTERING CHILLED WATERtemperature and remote contacts have occurred.

NOTE: Overriding the CHILLER START/STOP, WATER/ BRINE CONTROL POINT, and ACTIVE DEMAND LIMIT values by CCN devices (with a priority less than 4) during the ice build period is not possible. However, overriding can be accomplished with CCN during two-chiller lead/lag operation.

RETURN TO NON-ICE BUILD OPERATIONS — When the ice build function terminates, the chiller returns to normal temperature control and start/stop schedule operation. If the CHILLER START/STOP or WATER/BRINE CONTROL POINT has been forced (with a priority less than 4), before the start of ice build operation, then CHILLER START/STOP and WATER/BRINE CONTROL POINT forces are removed; that is, under these circumstances, the ice build operation takes precedence over the force.

Attach to Network Device Control — One of the

selections on the SERVICE menu is ATTACH TO NETWORK DEVICE. See Fig. 12. This table serves the following purposes:

• uploads the occupancy schedule number (OCCPC03S), if

changed, as deﬁned in the CONFIG screen (SCHEDULE NUMBER).

• attaches the LID to any CCN device, if the chiller has been

connected to a CCN network. This may include other PIC controlled chillers.

• uploads changes from a new PSIO or LID module or up-

graded software.

Figure 20 shows the ATTACH TO NETWORK DEVICE table as it appears on the LID. The LOCAL entry is always the PSIO module address of the chiller the LID is mounted on. Whenever the controller identiﬁcation of the PSIO is changed, this change is reﬂected on the bus and address for the LOCAL DEVICE of the ATTACH TO DEVICE screen automatically.

NAME DESCRIPTOR

Fig. 20 — Example of Attach to Network

Device Screen

Whenever the ATTACH TO NETWORK DEVICE table is accessed, no information can be read from the LID on any device until you attach one of the devices listed on the display. As soon as this screen appears, the LID erases information about the module to which it was attached to make room for information on another device. Therefore, a CCN module must be attached when this screen is entered.

To attach to a device listed on this screen, highlight it using the SELECT

softkey. Then press the ATTACH soft-

key.The message, UPLOADINGTABLES, PLEASE WAIT , ﬂashes. The LID then uploads the highlighted device or module. If the device address cannot be found, the message, COMMUNICATION FAILURE, appears. The LID then reverts to the ATTACH TO NETWORK DEVICE screen. Try another device or check the address of the device that did not attach. The upload process time for each CCN module is different. In general, the uploading process takes 3 to 5 minutes.

NOTE: Before leaving the ATTACH TO NETWORK DEVICE screen, select the LOCAL device. Otherwise, the LID will be unable to display information on the local chiller.

ATTACHINGTO OTHER CCN MODULES — If the chiller PSIO has been connected to a CCN network or other PIC controlled chillers through CCN wiring, the LID can be used to view or change parameters on the other controllers. Other PIC chillers can be viewed and set points changed (if the other unit is in CCN control) if desired from this particular LID module.

To view the other devices, access the ATTACH TO NETWORK DEVICE table. Move the highlight bar to any

device number. Press the SELECT

softkey to change to the bus number and address of the module to be viewed. Press the ENTER

softkey. Press the EXIT softkey to return to

the ATTACH TO NETWORK DEVICE table. If the device number is not valid, the message, COMMUNICATION FAILURE, displays. Enter a new address number or check the wiring. If the device is communicating properly, the message, UPLOAD IN PROGRESS, displays and the new device can now be viewed.

Whenever there is a question regarding which CCN device the LID is currently showing, check the device name descriptor on the upper left hand corner of the LID screen. See Fig. 20.When the CCN device has been viewed, use the ATTACH TO NETWORK DEVICE table to attach to the PSIO that is on the chiller. From the ATTACH TO NETWORK DEVICE table , highlight LOCAL, and press the

SELECT

softkey.Then, press the ATTACH softkey to up-

load the LOCAL device. The PSIO will upload.

Page 42

NOTE: The LID does not automatically re-attach to the PSIO module on the chiller. Access the ATTACH TO NETWORK DEVICE table, scroll to LOCAL, and press the

ATTACH

softkey to upload the local device. The software

for the local chiller will now be uploaded.

Service Operation — Figure 16 shows an overview of

the service menu. TO ACCESS THE SERVICE SCREENS

1. On the MENU screen, press the SERVICE softkeys now correspond to the numerals 1, 2, 3, and 4.

NOTE: The factory-set password is1-1-1-1.Seethe Input Service Conﬁgurations section, page 54, for information on how to change a password.

2. Press the four digits of your password, one at a time. An asterisk (*) appears as you enter each digit.

If the password is incorrect, an error message is displayed. If this occurs, return to Step 1 and try to access the SERVICE tables again. If the password is correct, the

softkey labels change to NEXT

SELECT

, and EXIT , and the LID screen displays the

following SERVICE tables:

• Alarm History

• Control Test

• Control Algorithm Status

• Equipment Conﬁguration

• Equipment Service

• Time and Date

• Attach to Network Device

• Log Out of Device

• Controller Identiﬁcation

• LID Conﬁguration

See Fig. 16 for additional screens and tables available form the SERVICE tables listed above. Use the EXIT return to the MENU screen.

TO LOG OFF — Access the LOG OUT OF DEVICE table from the SERVICEmenu. The LID exits the SERVICEmenu. T ore-enter the SERVICE menu, you must re-enter your password as described above.

NOTE: To prevent unauthorized persons from accessing the LID service screens, the LID automatically signs off and password-protects itself if a key has not been pressed for 15 minutes. The sequence is as follows. Fifteen minutes after the last key is pressed, the default screen displays, the LID screen light goes out (analogous to a screen saver), and the LID logs out of the password-protected SERVICE menu. Other screens and menus, such as the STATUS screen can be accessed without the password by pressing the appropriate softkeys.

HOLIDAY SCHEDULING (Fig. 21) — The time schedules may be conﬁgured for special operation during holiday periods. When modifying a time period, an ‘‘H’’ at the end of the days of the week ﬁeld signiﬁes that the period is applicable to a holiday. (See Fig. 14.)

The broadcast function must be activated for the holidays conﬁgured on the HOLIDEF screen to work properly. Access the BRODEF screen from the EQUIPMENT CONFIGURATION table and set the parameter that activates the BRODEF function to YES. Note that, when the chiller is connected to a CCN network, only one chiller or CCN device can be conﬁgured to be the broadcast device. The controller that is conﬁgured to be the broadcaster is the device responsible for transmitting holiday, time, and daylightsavings dates throughout the network.

softkey.The

, PREVIOUS ,

softkey to

EF, EX, FA CHLR HOLDY01S CONFIGURATION SELECT

Fig. 21 — Example of Holiday Period Screen

To view or change the holiday periods for up to 18 dif-

ferent holidays, perform the following operation:

1. At the Menu screen, press SERVICE

to access the

SERVICE menu.

2. If not logged on, follow the instructions for entering your password. See the section, ToAccess the Service Screens, page 42. Once logged on, press NEXT until

EQUIPMENT CONFIGURATION is highlighted.

3. Press the SELECT softkey to access the EQUIPMENT CONFIGURATION tables.

4. Press NEXT until HOLIDEF is highlighted. This is the holiday deﬁnition table.

5. Press SELECT to access the HOLIDEF screen. This screen lists 18 holiday tables.

6. Press NEXT to highlight the holiday table that you wish to view or change. Each table is one holiday pe-

riod, starting on a speciﬁc date, and lasting up to 99 days.

Page 43

7. Press SELECT to access the holiday table. The LID screen now shows the holiday start month and day, and

how many days the holiday period will last. See Fig. 24.

8. Press NEXT or PREVIOUS to highlight HOLIDAY START MONTH, START DAY,orDURATION.

9. Press SELECT to modify the month, day, or duration.

10. Press INCREASE or DECREASE to change the selected value.

If the checks are successful, the chilled water/brine pump relay is energized. Five seconds later, the condenser pump relay is energized. One minute later the PIC monitors the chilled water and condenser water ﬂow switches, and waits until the WATER FLOW VERIFY TIME (operator conﬁg- ured, default 5 minutes) to conﬁrm ﬂow. See the SERVICE1 screen or Table2, Example 8.After ﬂow is veriﬁed, the chilled water/brine temperature is compared to WATER/BRINE CON- TROL POINT plus DEADBAND. If the temperature is less than or equal to this value, the PIC turns off the condenser pump relay and goes into a RECYCLE mode.

If the water/brine temperature is high enough, the start-up sequence continues and checks the guide vane position. If the guide vanes are more than 6% open, the start-up waits until the PIC closes the vanes. If the vanes are closed, and the oil pump pressure is less than 3 psid (21 kPad), the oil pump relay is then energized. The PIC then waits a minimum of 15 seconds (maximum 5 minutes) to verify that the compressor oil pressure (OIL PRESSURE on the STATUS01 screen) has reached 15 psid (103 kPad). At the same time, the PIC waits up to 30 seconds to verify that the gear oil pressure (GEAR OIL PRESSURE on the STATUS04 screen) has reached 24 psi (166 kPa). After the oil pressures are veriﬁed, the PIC waits 10 seconds, and then the compressor start relay (1CR) is energized to start the compressor.

11. Press ENTER to save the changes.

12. Press EXIT to return to the previous menu.

START-UP/SHUTDOWN/

RECYCLE SEQUENCE (Fig. 22)

Local Start-Up —

is initiated by pressing the LOCAL on the default LID screen. Local start-up can proceed if the

OCCUPIED ? parameter on the STATUS01 table is set to YES and after the internal 15-minute start-to-start timer and the stop-to-start inhibit timer have expired.

The CHILLER START/STOP parameter on the STA- TUS01 screen may be overridden to start, regardless of the time schedule, in order to start the chiller locally. Also, the remote contacts may be enabled through the LID and closed to initiate a start-up.

Whenever the chiller is in LOCAL control mode, the PIC waits for the current time to coincide with an occupied time period as conﬁgured in the local time schedule (OCCPC01S) and for the remote contacts to close, if enabled. The PIC then performs a series of pre-start checks to verify that all pre-start alerts and safeties are within the limits shown in Table 3. The RUN STATUS line on the STATUS01 screen now reads STARTUP.

Local start-up (or a manual start-up)

menu softkey which is

LEGEND

A—START INITIATED — Prestart checks made; chilled water B—Condenser water pump started (5 seconds after A).

C—Water ﬂows veriﬁed (one minute to 5 minutes maximum

D—Oil pressure veriﬁed (for compressor, 15 seconds minimum,

E—Compressor motor starts, compressor ontime and service

F—SHUTDOWN INITIATED — Compressor motor stops, guide

G—After the post-lube period, oil and evaporator pumps deener-

O/A — Restart permitted (both inhibit timers expired) (minimum of

pump started.

afterA). Chilledwater temperature checkedagainst controlpoint. Guide vaneschecked for closure. Oil pumpsstarted; tower fan control enabled.

300 seconds maximum, after C; for gear, within 30 seconds after C).

ontime starts, 15-minute inhibit timer starts (10 seconds after D). Start-in-12 hours counter advances by one.

vanesclose, compressor ontimeand service ontimestops,stopto-start inhibit timer starts.

gized. Post-lube conﬁgurable to between one and 5 minutes after Step F.

15 minutes after E; minimum of 1 minute after F).

Fig. 22 — Control Sequence

Page 44

If any of these requirements are not met, the PIC aborts the start and displays the applicable pre-start mode of failure on the LID default screen. A pre-start failure does not advance the STARTSIN 12 HOURS counter(STATUS01 screen). Any failure after the 1CR relay has energized causes a safety shutdown, advances the STARTS IN 12 HOURS counter by one, and displays the applicable shutdown status on the LID display.

Shutdown Sequence — The chiller shuts down if any

of the following occurs:

• the STOP button on the control panel is pressed for at least

one second. The alarm light blinks once to conﬁrm the stop command.

• a recycle condition is present (see Chilled Water Recycle

Mode section).

• the OCCUPIED ? parameter on the STATUS01 screen reads

NO; that is, the chiller is not scheduled to run at the current time and date.

• the remote contact opens.

• the CHILLER START/STOP status is overridden to STOP

from the CCN network or the LID.

When a stop signal occurs, the shutdown sequence ﬁrst stops the compressor by deactivating the start relay.A status message, SHUTDOWN IN PROGRESS, COMPRESSOR DEENERGIZED, displays. The guide vanes are then brought to the closed position. The oil pump relay and the chilled water/brine pump relay are shut down 60 seconds after the compressor stops. The condenser water pump shuts down when the condenser refrigerant temperature is less than the condenser pressure override minus 5 psi (34 kPa) or is less than or equal to the entering condenser water temperature plus 3° F (2° C). The stop-to-start timer now begins to count down. If the value of the start-to-start timer is still greater than the value of the start-to-stop timer, then the start-tostart time is displayed on the LID.

There are certain conditions during shutdown that can change this sequence:

• if the COMPRESSOR MOTOR LOAD (STATUS01 screen)

is greater than 10% after shutdown or the starter contacts remain energized, the oil pump and chilled water pump remain energized and the alarm is displayed

• if the ENTERING CONDENSER WA TER(STATUS01 screen)

temperature is greater than 115 F (46 C) at shutdown, the condenser pump is deenergized after the 1CR compressor start relay

• if the chiller shuts down due to low refrigerant tempera-

ture, the chilled water pump keeps running until the LEAV-

ING CHILLED WATER temperature is greater than the WATER/BRINE CONTROL POINT plus 5° F (3° C).

Automatic Soft StopAmps Threshold — The au-

tomatic soft stop amps threshold is an operator conﬁgured value that closes the guide vanes of the compressor automatically when a non-recycle, non-alarm stop signal occurs before the compressor motor is deenergized.

If the STOP button on the control panel is pressed, the guide vanes close to a preset amperage percent or until the guide vane is less than 2% open. The compressor then shuts off.

If the chiller enters an alarm state or if the compressor enters a RECYCLE mode, the compressor is deenergized immediately.

To activate the automatic soft stop amps threshold, access the SERVICE1screen. Set the SOFT STOP AMPS THRESH- OLD parameter value to the percent of amps at which the motor will shut down. The default setting is 100% amps (no soft stop).

When the automatic soft stop amps threshold is being applied, a status message, SHUTDOWN IN PROGRESS, COMPRESSOR UNLOADING, displays.

Chilled Water Recycle Mode — When the compres-

sor is running under light load conditions, the chiller may cycle off and wait until the load increases to restart again. This cycling is normal and is known as recycle. A recycle shutdown is initiated when any of the following occurs:

• when the chiller is operating under the control of the leav-

ing chilled water temperature (that is, when the ECW CON- TROL OPTION on the CONFIG screen is disabled), the differencebetween the LEAVINGCHILLED WATER tem- perature and ENTERING CHILLED WATER temperature is less than the RECYCLE SHUTDOWN DELTA T (found in the SERVICE1 table) and the LEAVING CHILLED WA- TER TEMP is below the WA TER/BRINECONTROL POINT, and the WATER/BRINE CONTROL POINT has not in- creased in the last 5 minutes

• when the chiller is operating under the control of the en-

tering chilled water temperature (that is, the ECW CON-

TROL OPTION is enabled), the difference between the ENTERING CHILLED WA TERtemperature and the LEAVING CHILLED WATER temperature is less than the RECYCLE SHUTDOWN DELTA T (found in the SERV-

ICE1 table) and the ENTERING CHILLED WATER tem- perature is below the WATER/BRINE CONTROL POINT, and the WATER/BRINE CONTROL POINT has not in- creased in the last 5 minutes

• when the LEAVING CHILLED WA TERtemperature is within

3° F (2° C) of the BRINE REFRIG TRIPPOINT. (See the SERVICE1 screen.)

When the chiller is in RECYCLE mode, the chilled water pump relay remains energized so that the chilled water temperature can be monitored for increasing load. The recycle control uses the RECYCLE RESTART DELTA T value to check when the compressor should be restarted. This is an operator-conﬁgured value that defaults to 5° F (3° C). The value can be viewed/modiﬁed on the SERVICE1 screen. The compressor restarts when:

• the chiller is operating under leaving chilled water tem-

perature control and the LEAVING CHILLED WATER temperature is greater than the WATER/BRINE CON- TROL POINT plus the RECYCLE RESTART DELTA T; or

• the chiller is operating under entering chilled water tem-

perature control and the ENTERING CHILLED WATER temperature is greater than the WATER/BRINE CON- TROL POINT plus the RECYCLE RESTART DELTA T.

Once these conditions are met, the compressor initiates a start-up, with a normal start-up sequence.

An alert condition may be generated if 5 or more recycles occur in less than 4 hours. Because excessive recycling can reduce chiller life, compressor recycling caused by extremely low loads should be reduced. To accomplish this, use the time schedule to shut the chiller down during periods of known low load operation or increase the chiller load by running the fan systems. If the hot gas bypass is installed, adjust the values to ensure that hot gas is energized during light load conditions. Increase the RECYCLE RESTARTDELT A T value on the SERVICE1 screen to lengthen the time between restarts.

The chiller should not be operated below design minimum load without a hot gas bypass installed on the chiller.

Page 45

Safety Shutdown — A safety shutdown is identical to

a manual shutdown with the exception that the LID displays the reason for the shutdown, the alarm light blinks continuously, and the spare alarm contacts are energized. A safety

shutdown requires that the RESET order to clear the alarm. If the alarm continues, the alarm

light continues to blink. Once the alarm is cleared, the operator must press the CCN the chiller.

Do not reset starter loads or any other starter safety for 30 seconds after the compressor has stopped. Voltage output to the compressor start signal is maintained for 10 seconds to determine starter fault.

or LOCAL softkeys to restart

softkey be pressed in

BEFORE INITIAL START-UP

Job Data Required

• list of applicable design temperatures and pressures (product data submittal)

• certiﬁed drawings of the chiller

• starting equipment details and wiring diagrams

• diagrams and instructions for special controls or options

• installation instructions

• pumpout unit instructions

Remove Shipping Packaging— Remove any pack-

aging material from the control center, power panel, guide vane actuator, motor and bearing temperature sensor covers, and the factory-mounted starter.

MOTOR

The motor may be provided with a shipping brace or shipping bolt (normally painted yellow) to prevent shaft movement during transit. It must be removed prior to operation. See Fig. 24.

Equipment Required

• mechanic’s tools (refrigeration)

• digital volt-ohmmeter (DVM)

• clamp-on ammeter

• electronic leak detector

• absolute pressure manometer or wet-bulb vacuum indicator (Fig. 23)

• 500 v insulation tester (megohmmeter) for compressor motors with nameplate voltage of 600 v or less, or a 5000 v insulation tester for compressor motor rated above 600 v

Fig. 23 — Typical Wet-Bulb Type

Vacuum Indicator

Usingthe Economizer/Storage VesselandPumpoutSystem—

fer Procedures section, page 63 for: pumpout system preparation, refrigerant transfer, and chiller evacuation.

Refer to the Pumpout and Refrigerant Trans-

Fig. 24 — Shipping Bolt on Open Drive Motor

The motor should be inspected for any temporary, yellow caution tags with legends that convey information concerning actions necessary before the motor can be safely operated.Any slushing compound on the shaft or other parts must be removed using a petroleum type solvent. Observe proper safety precautions.

NOTE: If a shipping bolt was used to restrain the rotor, the Westinghouse logo must be installed over the hole in the endcover.The logo, the gasket, and hardware can be found with the parts that have been shipped loose. (Usually these are packed inside the main power lead box.)

EXTERNALGEAR — Remove any packaging material that may be on the external gear. Be sure that the breather is in place and free of any obstructions.

Motor Electrical Connection — All interconnect-

ing wiring for controls and grounding should be in strict compliance with both the (NEC) National Electrical Code and any local requirements.

The main lead box furnished with the motor has been sized to provide adequate space for making up connections between the motor lead cables and the incoming power cables. The bolted joints between the motor lead and the power cables must be made and insulated in a workman-like manner following the best trade practices.

Fabricated motors are provided with 2 stainless steel grounding pads drilled and tapped with the NEMA (National Electrical Manufacturers Association) 2-hole pattern (two tapped holes on 13⁄4in. centers). Fan cooled cast frames are provided with a special grounding bolt. The motor should be grounded by a proper connection to the electrical system ground.

⁄2-13

Page 46

The rotation direction of the motor is shown either on the motor nameplate or on the certiﬁed drawing. Information on the required phase rotation of the incoming power for this motor may also be found on the nameplate or drawing. If either is unknown, the correct sequence can be determined as follows. While the motor is uncoupled from the load, start the motor and observe the direction of rotation. Allow the motor to achieve full speed before disconnecting it from the power source. Refer to Motor Pre-Start Checks (page 51) for information concerning initial start-up. If the resulting rotation is incorrect, it can be reversed by interchanging any 2 incoming cables.

Motor Auxiliary Devices — Auxiliary devices such

as resistance temperature detectors, thermocouples, thermoguards, etc., generally terminate on terminal blocks located in the auxiliary terminal box on the motor. Other devices may terminate on their own enclosures elsewhere on the motor.Such information can be obtained by referring to the certiﬁed drawing. Information regarding terminal designations and the connection of auxiliary devices can be obtained from the auxiliary drawings referenced by the outline drawing.

If the motor is provided with internal space heaters, to ensure proper heater operation, the incoming voltage supplied to them must be exactly as shown by either the nameplate on the motor or the outline drawing. Exercise caution any time contact is made with the incoming space heater circuit, because space heater voltage is often automatically applied when the motor is shut down.

Open Oil Circuit Valves — Check that the oil ﬁlter

isolation valves for both the compressor and external gear are open by removing the valve cap and checking the valve stem. (See Scheduled Maintenance, Changing the Oil Filters, page 76.)

Do not use air or oxygen as a means of pressurizing the chiller. Some mixtures of HFC-134a and air can undergo combustion.

Leak Test the Chiller — Due to regulations regarding

refrigerant emissions and the dif ficulties associated with separating contaminants from refrigerant, Carrier recommends the following leak test procedures. See Fig. 25 for an outline of the leak test procedures. Refer to Tables 5A and 5B for refrigerant pressure/temperature values and to the Pumpout and Refrigerant Transfer Procedures section, page 63.

1. If the pressure readings are normal for the chiller condition:

a. Evacuate the nitrogen holding charge from the ves-

sels, if present.

b. Raise the chiller pressure, if necessary, by adding re-

frigerant until the pressure is at an equivalent saturated pressure for the surrounding temperature. Follow the pumpout procedures in the Pumpout and Refrigerant Transfer Procedures section, page 63.

Never charge liquid refrigerant into the chiller if the pressure in the chiller is less than 35 psig (241 kPa). Charge as a gas only, with the cooler and condenser pumps running, until this pressure is reached, using PUMPDOWN/ LOCKOUT and TERMINATE LOCKOUT mode on the PIC. Flashing of liquid refrigerant at low pressures can cause tube freeze-up and considerable damage.

Tighten All Gasketed Joints and Guide Vane Shaft Packing —

by the time the chiller arrives at the jobsite. Tighten all gasketed joints and the guide vane shaft packing to ensure a leak-tight chiller.

NOTE: Check the chiller cold alignment. Refer to Chiller Alignment in the General Maintenance section, page 71.

Gaskets and packings normally relax

Check Chiller Tightness — Figure 25 outlines the

proper sequence and procedures for leak testing.

17EX chillers may be shipped with the refrigerant contained in the economizer/storage vessel and the oil charge shipped in the compressor. The cooler/condenser vessels have a 15 psig (103 kPa) refrigerant charge. Units may also be ordered with the refrigerant shipped separately, along with a 15 psig (103 kPa) nitrogen-holding charge in each vessel.

To determine if there are any leaks, the chiller should be charged with refrigerant. Use an electronic leak detector to check all ﬂanges and solder joints after the chiller is pressurized. If any leaks are detected, follow the leak test procedure.

If the chiller is spring isolated, keep all springs blocked in both directions in order to prevent possible piping stress and damage during the transfer of refrigerant from vessel to vessel during the leak test process or any time refrigerant is transferred. Adjust the springs when the refrigerant is in operating condition and when the water circuits are full.

RefrigerantTracer— Carrier recommends using an en-

vironmentally acceptable refrigerant tracer for leak testing with an electronic detector.

Ultrasonic leak detectors also can be used if the chiller is under pressure.

Run the chiller water pumps whenever transferring, removing, or charging refrigerant.

c. Leak test chiller as outlined in Steps3-9.

2. If the pressure readings are abnormal for chiller conditions:

a. Prepare to leak test chillers shipped with refrigerant

(Step 2h).

b. Check for large leaks by connecting a nitrogen bottle

and raising the pressure to 30 psig (207 kPa). Soap test all joints. If the test pressure holds for 30 minutes,

prepare to test for small leaks (Steps 2g - h). c. Plainly mark any leaks that are found. d. Release the pressure in the system. e. Repair all leaks. f. Retest the joints that were repaired. g. After successfully completing the test for large leaks,

remove as much nitrogen, air, and moisture as pos-

sible, given the fact that small leaks may be present in

the system. This can be accomplished by following

the dehydration procedure, outlined in the Chiller

Dehydration section, page 49. h. Slowly raise the system pressure to the equivalent satu-

rated pressure for the surrounding temperature but no

less than 35 psig (241 kPa) by adding HFC-134a

refrigerant. Proceed with the test for small leaks

(Steps 3-9).

3. Check the chiller carefully with an electronic leak detector, or soap bubble solution.

Page 47

Fig. 25 — 17EX Leak Test Procedures

Page 48

Table 5A — HFC-134a Pressure — Temperature (F)

TEMPERATURE (F) PRESSURE (psi)

0 6.50 2 7.52 4 8.60 6 9.66 8 10.79

10 11.96 12 13.17 14 14.42 16 15.72 18 17.06

20 18.45 22 19.88 24 21.37 26 22.90 28 24.48

30 26.11 32 27.80 34 29.53 36 31.32 38 33.17

40 35.08 42 37.04 44 39.06 46 41.14 48 43.28

50 45.48 52 47.74 54 50.07 56 52.47 58 54.93

60 57.46 62 60.06 64 62.73 66 65.47 68 68.29

70 71.18 72 74.14 74 77.18 76 80.30 78 83.49

80 86.17 82 90.13 84 93.57 86 97.09 88 100.70

90 104.40 92 108.18 94 112.06 96 116.02 98 120.08

100 124.23 102 128.47 104 132.81 106 137.25 108 141.79

110 146.43 112 151.17 114 156.01 116 160.96 118 166.01

120 171.17 122 176.45 124 181.83 126 187.32 128 192.93

130 198.66 132 204.50 134 210.47 136 216.55 138 222.76 140 229.09

Table 5B — HFC-134a Pressure — Temperature (C)

TEMPERATURE (C) PRESSURE (kPa)

-18.0 44.8

-16.7 51.9

-15.6 59.3

-14.4 66.6

-13.3 74.4

-12.2 82.5

-11.1 90.8

-10.0 99.4

-8.9 108.0

-7.8 118.0

-6.7 127.0

-5.6 137.0

-4.4 147.0

-3.3 158.0

-2.2 169.0

-1.1 180.0

0.0 192.0

1.1 204.0

2.2 216.0

3.3 229.0

4.4 242.0

5.0 248.0

5.6 255.0

6.1 261.0

6.7 269.0

7.2 276.0

7.8 284.0

8.3 290.0

8.9 298.0

9.4 305.0

10.0 314.0

11.1 329.0

12.2 345.0

13.3 362.0

14.4 379.0

15.6 396.0

16.7 414.0

17.8 433.0

18.9 451.0

20.0 471.0

21.1 491.0

22.2 511.0

23.3 532.0

24.4 554.0

25.6 576.0

26.7 598.0

27.8 621.0

28.9 645.0

30.0 669.0

31.1 694.0

32.2 720.0

33.3 746.0

34.4 773.0

35.6 800.0

36.7 828.0

37.8 857.0

38.9 886.0

40.0 916.0

41.1 946.0

42.2 978.0

43.3 1010.0

44.4 1042.0

45.6 1076.0

46.7 1110.0

47.8 1145.0

48.9 1180.0

50.0 1217.0

51.1 1254.0

52.2 1292.0

53.3 1330.0

54.4 1370.0

55.6 1410.0

56.7 1451.0

57.8 1493.0

58.9 1536.0

60.0 1580.0

Page 49

4. Leak Determination — If an electronic leak detector indicates a leak, use a soap bubble solution, if possible, to conﬁrm it. Total all leak rates for the entire chiller. Leakage for the entire chiller at rates greater than the EPA (Environmental Protection Agency) guidelines or local codes must be repaired. Note the total chiller leak rate on the start-up report. This leak rate repair is only for new startups. See page 67 in General Maintenance section for recommendations on checking leak rates and leak repairs for operating chillers.

5. If no leak is found during the initial start-up procedures, complete the transfer of refrigerant gas (see Pumpout and Refrigerant Transfer Procedures section, page 63.)

6. If no leak is found after a retest: a. Transfer the refrigerant to the economizer/storage ves-

sel or other storage tank and perform a standing vacuum test as outlined in the Standing Vacuum Test section, this page.

b. If the chiller fails this test, check for large leaks

(Step 2b).

c. Dehydrate the chiller if it passes the standing vacuum

test. Follow the procedure in the Chiller Dehydration section, below. Charge chiller with refrigerant (see Pumpout and Refrigerant Transfer Procedures section, page 63).

7. If a leak is found, pump the refrigerant back into the economizer/storage vessel or other storage tank.

8. Transfer the refrigerant until the chiller pressure is 18 in. Hg (41 kPa absolute).

9. Repair the leak and repeat the procedure, beginning from Step 2g to ensure a leak-tight repair. (If chiller is opened to the atmosphere for an extended period, evacuate it before repeating the leak test.)

StandingVacuumTest— When performing the stand-

ing vacuum test or chiller dehydration, use a manometer or a wet bulb indicator. Dial gages cannot indicate the small amount of acceptable leakage during a short period of time.

1. Attach an absolute pressure manometer or wet bulb indicator to the chiller.

2. Evacuate the vessel (see Pumpout and Refrigerant Transfer Procedures section, page 63) to at least 18 in. Hg vac, ref 30-in. bar (41 kPa), using a vacuum pump or the pumpout unit.

3. Valve off the pump to hold the vacuum and record the manometer or indicator reading.

4. a. If the leakage rate is less than 0.05 in. Hg (0.17 kPa)

in 24 hours, the chiller is sufficiently tight.

b. If the leakage rate exceeds 0.05 in. Hg (0.17 kPa) in

24 hours, repressurize the vessel and test for leaks. If refrigerant is available in the other vessel, pressurize by following Steps 2-10 of Return Chiller To Normal Operating Conditions section, page 67. If not, use nitrogen and a refrigerant tracer. Raise the vessel pressure in increments until the leak is detected. If refrigerant is used, the maximum gas pressure is approximately 70 psig (483 kPa) at normal ambient temperature.

5. Repair the leak, retest, and proceed with dehydration.

Do not start or megohm-test the compressor motor or oil pump motor, even for a rotation check, if the chiller is under dehydration vacuum. Insulation breakdown and severe damage may result.

Dehydration is readily accomplished at room temperatures. Using a cold trap (Fig. 26) may substantially reduce the time required to complete the dehydration. The higher the room temperature, the faster dehydration takes place. At low room temperatures, a very deep vacuum is required for boiling off any moisture. If low ambient temperatures are involved, contact a qualiﬁed service representative for the dehydration techniques required.

Perform dehydration as follows:

1. Connect a high capacity vacuum pump (5 cfm

[0.002 m

/s] or larger is recommended) to the refrigerant charging valve (Fig. 6). Tubingfromthe pump to the chiller should be as short and as large in diameter as possible to provide the least resistance to gas ﬂow.

2. Use an absolute pressure manometer or a wet bulb vacuum indicator to measure the vacuum. Open the shutoff valve to the vacuum indicator only when taking a reading. Leave the valve open for 3 minutes to allow the indicator vacuum to equalize with the chiller vacuum.

3. Open all isolation valves (if present), if the entire chiller is to be dehydrated.

4. With the chiller ambient temperature at 60 F (15.6 C) or higher,operate thevacuum pump until the manometer reads

29.8 in. Hg vac, ref 30 in. bar. (0.1 psia)(–100.61 kPa) or a vacuum indicator reads 35 F (1.7 C). Operate the pump an additional 2 hours.

Do not apply a greater vacuum than 29.82 in. Hg vac (757.4 mm Hg) or go below 33 F (0.56 C) on the wet bulb vacuum indicator. At this temperature/pressure, isolated pockets of moisture can turn into ice. The slow rate of evaporation (sublimation) of ice at these low temperatures/ pressures greatly increases dehydration time.

5. Valve off the vacuum pump, stop the pump, and record the instrument reading.

6. After a 2-hour wait, take another instrument reading. If the reading has not changed, dehydration is complete. If the reading indicates a vacuum loss, repeat Steps 4 and 5.

7. If the reading continues to change after several attempts, perform a leak test up to the maximum 180 psig (1241 kPa) pressure. Locate and repair the leak, and repeat dehydration.

Chiller Dehydration — Dehydration is recommended

if the chiller has been open for a considerable period of time, if the chiller is known to contain moisture, or if there has been a complete loss of chiller holding charge or refrigerant pressure.

Fig. 26 — Dehydration Cold Trap

Page 50

Inspect Water Piping — Refer to the piping diagrams

provided in the certiﬁed drawings and the piping instructions in the 17EX Installation Instructions manual. Inspect the piping to the cooler and condenser. Be sure that ﬂow directions are correct and that all piping speciﬁcations have been met.

Piping systems must be properly vented, with no stress on the waterbox nozzles and covers. Water ﬂows through the cooler and condenser must meet job requirements. Measure the pressure drop across the cooler and condenser.

Water must be within design limits, clean, and treated to ensure proper chiller performance and reduce the potential of tube damage due to corrosion, scaling, or erosion. Carrier assumes no responsibility for chiller damage resulting from untreated or improperly treated water.

CheckOptional Pumpout Compressor WaterPiping —

to ensure that the pumpout condenser water has been piped in. Check for ﬁeld-supplied shutoff valves and controls as speciﬁed in the job data. Check for refrigerant leaks on ﬁeldinstalled piping.

If the optional pumpout system is installed, check

Check Relief Devices — Be sure that relief devices

have been piped to the outdoors in compliance with the latest edition of ANSI/ASHRAE (American National Standards Institute/American Society of Heating, Refrigeration, andAir Conditioning Engineers) Standard 15 and applicable local safety codes. Piping connections must allow for access to the valve mechanism for periodic inspection and leak testing.

Relief valves are set to relieve at the 225 psig (1551 kPa) chiller design pressure.

Inspect Wiring

Do not check voltage supply without proper equipment and precautions. Serious injury may result. Follow power company recommendations.

Do not apply any kind of test voltage, including to check compressor oil pump even for a rotation check, if the chiller is under a dehydration vacuum. Insulation breakdown and serious damage may result.

1. Examine wiring for conformance to job wiring diagrams and to all applicable electrical codes.

2. Compare the ampere rating on the starter nameplate with the compressor nameplate. The overload trip amps must be 108% to 120% of the rated load amps.

3. The starter for a centrifugal compressor motor must contain the components and terminals required for PIC refrigeration control. Check the certiﬁed drawings.

4. Check the voltage to the following components and compare to the nameplate values: compressor and gear oil pump contactors, pumpout compressor starter, and power panel.

5. Be sure that fused disconnects or circuit breakers have been supplied for the compressor and gear oil pumps, power panel, and pumpout unit.

6. Check that all electrical equipment and controls are properly grounded in accordance with job drawings, certiﬁed drawings, and all applicable electrical codes.

7. Make sure that the customer’s contractor has veriﬁed the proper operation of the pumps, cooling tower fans, and associated auxiliary equipment. This includes ensuring that motors are properly lubricated, have proper electrical supply, and have proper rotation.

8. Tighten all wiring connections to the plugs on the SMM, 8-input, and PSIO modules.

9. Ensure that the voltage selector switch inside the power panel is switched to the incoming voltage rating, 115 v. The 230 v alternative is not used.

10. On chillers with free-standing starters, inspect the power panel to ensure that the contractor has fed the wires into the bottom of the panel. Wiring into the top of the panel can cause debris to fall into the contactors. Clean and inspect the contactors if this has occurred.

Voltage to terminals LL1 and LL2 comes from a control transformer in a starter built to Carrier speciﬁcations. Do not connect an outside source of control power to the compressor motor starter (terminals LL1 and LL2). An outside power source will produce dangerous voltage at the line side of the starter, because supplying voltage at the transformer secondary terminals produces input level voltage at the transformer primary terminals.

CHECK INSULATION RESISTANCE — Before applying operating voltage to the motor, whether for checking rotation direction or for actual operation, measure the resistance of the stator winding insulation.

The test voltage, based on the motor operating voltage, is

as follows:

Operating Voltage DC Test Voltage

0- 900 500

901- 7000 1000

7001-14500 2500

This is particularly important if the motor may have been exposed to excessive dampness either during transit or while in storage. A ‘‘megger’’type instrument can be used to measure the insulation resistance. The test voltage should be applied between the entire winding (all winding leads connected together) and ground for approximately one minute with the winding at ambient temperature. The recommended minimum insulation resistance is determined as follows:

RM = KV + 1 Where RM = Recommended minimum insulation resis-

tance in megohms at 104° F (40° C) of the entire winding.

KV = Rated motor terminal to terminal voltage in

kilovolts (1000 volts = 1 KV).

On a new winding, where the contaminant-causing low insulation resistance is generally moisture, drying the winding through the proper application of heat normally increases the insulation resistance to an acceptable level. The following methods are acceptable for applying heat to a winding:

1. If the motor is equipped with space heaters, energize the

heaters to heat the winding.

Page 51

2. Direct current (as from a welder) can be passed through the winding. The total current should not exceed approximately 50% of the rated full load current. If the motor has only 3 leads, 2 must be connected together to form one circuit through the winding. In this case, one phase carries the full applied current and each of the others carries half of the applied current. If the motor has 6 leads (3 mains and 3 neutrals), the 3 phases should be connected into one series circuit.

3. Heated air can be blown either directly into the motor or into a temporary enclosure surrounding the motor. The source of heated air should preferably be electrical vs. fueled (such as kerosene), since a malfunction of the fuel burner could result in carbon entering the motor. Exercise caution when heating the motor with any source of heat other than self-contained space heaters. Raise the winding temperature at a gradual rate to allow any entrapped moisture to vaporize and escape without rupturing the insulation. The entire heating cycle should extend over 15 to 20 hours.

Insulation resistance measurements can be made while the winding is being heated. However, they must be corrected to 104 F (40 C) for evaluation since the actual insulation resistance decreases with increasing temperature. For a new winding, the insulation resistance approximately halves for each 18° F (10° C) increase in insulation temperature above the dew point.

Motor Pre-Start Checks — To prevent damage to the

motor, the following steps must be taken before initial startup:

1. Remove the shaft shipping brace (if supplied).

2. For sleeve bearing motors, the oil reservoir must be ﬁlled

with oil to the correct level. Use a rust and oxidation inhibited, turbine grade oil. The viscosity of the oil must be 32 ISO (150 SSU) at 100 F (37.7 C). Oil capacity in each of the two bearings is 0.6 gal. (2.3 L) per bearing. Use of Carrier Oil Speciﬁcation PP16-0 is approved, Carrier Part No. PP23BZ091 (Mobil DTE Light or Texaco Regal R+O32).

3. If possible, the shaft should be turned over by hand to

ensure that there is free rotation. On sleeve bearing motors, the shaft should be moved to both extremes of its end play while it is being rotated, and the oil rings should be viewed through the viewing ports in the top of the bearing housing to verify free ring rotation.

4. On fan-cooled motors, the area around the external fan

inlet should be checked for loose debris that could be drawn into the fan during operation.

5. All external, factory-made, bolted joints should be checked

for any looseness that may have occurred in transit. Refer to Table 6 for recommended bolt torques.

Table 6 — Recommended Motor Fastener

Bolt size1⁄

Grade SAE GR 5

Torque*

Ft-lbs 3.5 7 12 31 63 115 180 275 550 960

N.m 4.7 9.5 16 42 85 156 244 373 746 1302

Tightening Torques

(

⁄

(

⁄

(

⁄

(

⁄

(

⁄

(

⁄8( 1( 11⁄3( 11⁄

External Gear Pre-Start Checks

There are 2 service valves on the external gear oil lines. See Fig. 27. Open both valves before starting the chiller.

External gears are shipped without oil. Before start-up, the gear must be ﬁlled with the proper type and amount of oil.

Before starting the external gear, check for any signs of mechanical damage, such as damaged piping or accessories. Then, follow the procedures listed below.

1. Fill the gear and auxiliary sump (if applicable) with oil

to the level indicated next to the sight glass. Fill the gear to the proper level as follows. Make sure all external piping, gear oil cooler, and pumps are ﬁlled before conﬁrming the ﬁnal oil level. Fill to the oil level indicated next to the glass sight gage.

Add oil through the gear inspection cover.The inspection cover must be removed in order to add oil. Take care to seal the cover when it is replaced.

Never attempt to add or replace oil while the external gear is running unless a vertical sight glass is in use and the running oil level has been established and marked on the sight glass. Do not ﬁll beyond the indicated oil level. Excess lubrication increases the churning effect and may result in overheating and subsequent thinning of oil and possible damage to the rotating components.

2. The viscosity of the oil must be 68 ISO. Use of Carrier

oil, speciﬁcation PP16-2 is approved (Mobil DTE Heavy Medium or Texaco Regal UR & 068; Carrier Part No. PP23BB005).

3. Check that all electrical connections have been made and

are in working order. Check that all accessories are properly mounted.

4. Turn the gear shafts by hand with a spanner wrench to

conﬁrm that there are no obstructions to rotation.

5. Check that all couplings are properly aligned, mounted,

and keyed on the shaft extension.

6. Check that the inspection cover is securely fastened. See

Table 7 for recommended torque values.

7. For units operating in cold ambient temperatures, op-

tional heaters must be turned on and the oil temperature must be allowed to rise to at least 60 F (16 C) before start-up.

8. Start the chiller under as light a load as possible. Check

(

for oil leaks, unusual sounds, excessive vibration, and excessive heat. If an operating problem develops, shut down immediately and correct the problem before restarting.

Bolt size M4 M6 M8 M10 M12 M10 M12 M16

Grade DIN 8.8 DIN 12.9

Torque*

*Torque values based upon dry friction.

Ft-lbs 2 8 15 35 65 45 92 225

N.m 2.7 11 20 47 88 61 125 305

Page 52

Fig. 27 — External Gear Lubrication System

Page 53

Table 7 — Recommended Compressor and

External Gear Fastener Tightening Torques

FASTENER

DIAMETER (in.)

UNC Minimum Maximum

⁄

1 515 (698.3) 643 (871.9) 11⁄

⁄

13⁄

11⁄

⁄

2 2750 (3729.0) 3437 (4660.6)

⁄

21⁄

23⁄

*Dry fastener. NOTE: The torque values listed are to be used for end covers, seal

cages, shaft guards, inspection covers, and housing split line bolts, unless otherwise speciﬁed on the drawing or assembly instructions.

7 (9.5) 9 (12.2) 14 (19.0) 17 (23.1) 25 (33.9) 31 (42.0) 40 (54.2) 50 (67.8) 60 (81.4) 75 (101.7) 87 (118.0) 108 (137.0)

120 (162.7) 150 (203.4) 213 (288.8) 266 (360.7) 343 (465.1) 429 (581.7)

635 (861.1) 793 (1075.3)

896 (1215.0) 1120 (1518.7) 1175 (1593.3) 1468 (1990.6) 1560 (2115.4) 1950 (2644.2) 1828 (2478.8) 2286 (3099.8)

4022 (5453.8) 5027 (6816.6) 5500 (7458.6) 6875 (9322.5) 7456 (10,110.3) 9323 (12,642.0)

TORQUE*

Lb.-Ft. (N•m)

Carrier Comfort Network Interface — The Carrier

Comfort Network (CCN) communication bus wiring is supplied and installed by the electrical contractor. It consists of shielded, 3-conductor cable with drain wire.

The system elements are connected to the communication bus in a daisy chain arrangement. The positive pin of each system element communication connector must be wired to the positive pins of the system element on either side of it; the negative pins must be wired to the negative pins; the signal ground pins must be wired to signal ground pins.

To attach the CCN communication bus wiring, refer to the certiﬁed drawings and wiring diagrams. The wire is inserted into the CCN communications plug (COMM1) on the PSIO module. This plug also is referred to as J5.

NOTE: Conductors and drain wire must be 20AWG (American Wire Gage) minimum stranded, tinned copper. Individual conductors must be insulated with PVC, PVC/nylon, vinyl, Teﬂon,or polyethylene.An aluminum/polyester 100% foil shield and an outer jacket of PVC, PVC/nylon, chrome vinyl, or Teﬂonwith a minimum operating temperature range of –20 C to 60 C is required. See table below for cables that meet the requirements.

MANUFACTURER CABLE NO.

Alpha 2413 or 5463

American A22503

Belden 8772

Columbia 02525

When connecting the CCN communication bus to a system element, a color code system for the entire network is recommended to simplify installation and checkout. The following color code is recommended:

SIGNAL

Ground WHITE 2

CCN BUS CONDUCTOR

TYPE

INSULATION COLOR

+ RED 1 – BLACK 3

PSIO MODULE

COMM 1 PLUG (J5) PIN NO.

Check Starter

BE AWARE that certain automatic start arrangements can engage the starter. Open the disconnect ahead of the starter in addition to shutting offthe chiller and pump.

Use the instruction and service manual supplied by the starter manufacturer to verify that the starter has been installed correctly.

The main disconnect on the starter front panel may not deenergize all internal circuits. Open all internal and remote disconnects before servicing the starter.

Whenever a starter safety trip device activates, wait at least 30 seconds before resetting the safety. The microprocessor maintains its output to the 1CR relay for 10 seconds after starter safety shutdown to determine the fault mode of failure.

MECHANICAL STARTERS

1. Check all ﬁeld wiring connections for tightness, clear-

ance from moving parts, and correct connection.

2. Check the contactor(s) to be sure they move freely.Check

the mechanical interlock between contactors to ensure that the 1S and 2M contactors cannot be closed at the same time. Check all other electro-mechanical devices, such as relays and timers, for free movement. If the devices do not move freely, contact the starter manufacturer for replacement components.

3. Some dashpot-type magnetic overload relays must be filled

with oil at the jobsite. If the starter is equipped with devices of this type, remove the ﬂuid cups from these magnetic overload relays. Add dashpot oil to the cups per instructions supplied with the starter.The oil is usually shipped in a small container attached to the starter frame near the relays. Use only dashpot oil supplied with the starter. Do not substitute.

Factory-ﬁlled dashpot overload relays need no oil at startup, and solid-state overload relays do not have oil.

4. Reapply starter control power (not main chiller power)to

check the electrical functions. When using a reducedvoltage starter (such as a wye-delta starter) check the transition timer for proper setting. The factory setting is 30 seconds (±5 seconds), timed closing. The timer is adjustable in a range between 0 and 60 seconds, and settings other than the nominal 30 seconds may be chosen as needed (typically 20 to 30 seconds).

When the timer has been set, check that the starter (with relay 1CR closed) goes through a complete and proper

start cycle.

SOLID-STATE STARTERS

The solid-state starter is at line voltage when AC power is connected. Pressing the Stop button does not remove voltage. Use caution when adjusting the potentiometers on the equipment.

Page 54

1. Check that all wiring connections are properly terminated to the starter.

2. Verify that the ground wire to the starter is installed properly and is of sufficient size.

3. Verify that the motors are properly grounded to the starter .

4. Check that all the relays are properly seated in their sockets.

5. Verify that the proper AC input voltage is brought into the starter per the certiﬁed drawings.

6. Verify that the initial factory settings (i.e., starting torque, ramp potentiometers, etc.) are set per the manufacturer’s instructions.

Compressor Oil Charge — If oil is added, it must

meet Carrier’s speciﬁcation for centrifugal compressor use as described in the Scheduled Maintenance, Oil Speciﬁcations section (page 77).

Oil may be added through the compressor oil drain and charging valve (Fig. 2, Item 22) using a pump. The pump must be able to lift from 0 to 150 psig (0 to 1034 kPa), or above chiller pressure. However, an oil charging elbow on the seal-oil return chamber (Fig. 4, Item 3) allows oil to be added without pumping. The seal oil return pump automatically transfers the oil to the main oil reservoir.

Oil should only be charged or removed when the chiller is shut down. Maximum oil level is the middle of the upper sight glass.

Power Up the Controls and Check the Compressor Oil Heater —

ible in the compressor before energizing the controls.A separate disconnect energizes the oil heater and the control circuit. When ﬁrst powered, the LID should display the default screen within a short period of time.

The oil heater is energized by powering the control circuit. This should be done several hours before start-up to minimize oil-refrigerant dilution. The oil heater is controlled by the PIC and is powered through a contactor in the power panel. Starters contain a separate circuit breaker to power the heater and the control circuit. This arrangement allows the heater to energize when the main motor circuit breaker is off for service work or extended shutdowns. The oil heater relay status can be viewed on the STATUS02screen on the LID. Oil sump temperature can be viewed on the LID default screen.

SOFTWARE VERSION — The software version is always labeled on the PSIO module and on the back side of the LID module. The software number also appears on both the CONTROLLER IDENTIFICATIONand LID CONFIGURATION tables. See Fig. 15.

Be sure that an oil level is vis-

Set Up Chiller Control Conﬁguration

Do not operate the chiller before the control conﬁgurations have been checked and a Control Test has been satisfactorily completed. Protection by safety controls cannot be assumed until all control conﬁgurations have been conﬁrmed.

Input the Design Set Points — To modify the set

points, access the SETPOINT menu. (Press the MENU

SETPOINT base demand limit and the leaving chilled water, entering chilled water, and ice build set points. See Fig. 15 for the SETPOINT menu structure.

The PIC can control a set point according to ether the leaving or entering chilled water temperature. Tochange the type of control, access the CONFIG screen. Scroll down to highlight ECW CONTROL OPTION. To control the set point ac-

cording to the leaving chilled water, press the DISABLE softkey; to control the set point according to the entering

chilled water, press the ENABLE

softkeys.) From this menu, you can modify the

softkey.

and

Inputthe Local OccupiedSchedule (OCCPC01S)

To set up the occupied time schedule according to the

—

site requirements, access the SCHEDULE screen on the LID. (Press the MENU fault, factory-set schedule is 24 hours, occupied 7 days per

week including holidays. For more information about how to set up a time schedule, see the Controls section, page 11.

If the ice build option is being used, conﬁgure the ice build schedule (OCCPC02S).

If a CCN system is being installed or if a secondary time schedule is required, conﬁgure the CCN occupancy schedule (OCCPC03S to OCCPC99S). This task is normally done using a CCN Building Supervisor terminal, but it can also be done at the LID. For more information on CCN functions, see 17EX CCN supplement. Also, in this manual, see the section on Occupancy Schedule, page 32.

and SCHEDULE softkeys.) The de-

Input Service Conﬁgurations — The following con-

ﬁgurations are done from the SERVICE menu:

• password

• input time and date

• LID conﬁguration

• controller identiﬁcation

• service parameters

• equipment conﬁguration

• automated control test PASSWORD — You must enter a password whenever you

access the SERVICE screens. The default, factory-set password is1-1-1-1.Thepassword may be changed from the LID CONFIGURATION screen. To change the password:

1. Press the MENU

password and highlight LID CONFIGURATION. Press the SELECT

CONFIGURATION screen can be changed: BUS #,

ADDRESS #, BAUD RATE, US IMP/METRIC, and PASSWORD.

2. Use the ENTER

ﬁrst digit of the password is highlighted on the LID screen.

3. To change the digit, press the INCREASE

DECREASE

press the ENTER

4. The next digit is highlighted. Change it and the third and

fourth digits in the same way you changed the ﬁrst.

and SERVICE softkeys. Enter your

softkey. Only the last 5 entries on the LID

softkey to scroll to PASSWORD. The

softkey.When you see the digit you want,

softkey.

As you conﬁgure the 17EX chiller, write down all conﬁguration settings. A log, such as the one shown on pages CL-1 to CL-12, is a convenient way to list conﬁguration values.

Page 55

5. After the last digit is changed, the LID goes to the BUS # parameter. Press the EXIT

softkey to leave the

screen, record your password change, and return to the SERVICE menu.

BE SURE TO REMEMBER YOUR PASSWORD. Retain a copy of the password for future reference. If you forget your password, you will not be able to access the SERVICE menu unless you install and download a new PSIO module.

INPUT TIME AND DATE — Access the Time and Date table on the SERVICE menu. Input the present time of day, date, and day of the week. HOLIDAY TODAY should only be conﬁgured to YES if the present day is a holiday.

CHANGE THE LID CONFIGURATION IF NECESSARY — From the LID CONFIGURATION screen, the LID CCN address, units (English or SI), and password can be changed. If there is more than one chiller at the jobsite, change the LID address on each chiller so that each chiller has its own address. Note and record the new address. Change the screen to SI units as required, and change the password if desired.

To Change the LID Display From English to Metric Units — By default, the LID displays information in English units. To change to metric units:

1. Press the MENU and SERVICE softkeys. Enter your password and highlight LID CONFIGURATION. Press the SELECT softkey.

2. Use the ENTER softkey to scroll to US IMP/METRIC.

3. Press the softkeys that correspond to the units you want displayed on the LID (e.g., US or METRIC ).

MODIFY CONTROLLER IDENTIFICATION IF NECESSARY — The PSIO module address can be changed from the CONTROLLER IDENTIFICATION screen. If there is more than one chiller at the site, change the controller address for each chiller. Write the new address on the PSIO module for future reference.

INPUT EQUIPMENT SERVICE PARAMETERS IF NECESSARY— The EQUIPMENT SER VICEtable has 3 screens: SERVICE1, SERVICE2, and SERVICE3.

Conﬁgure SERVICE1 Table —Access the SERVICE1 table to modify or view the following:

Chilled Medium Water or Brine? Brine Refrigerant Trippoint Usually 3° F (1.7° C) below design

Surge Limiting or

Hot Gas Bypass Option

Minimum Load Points

(T1/P1)

Full Load Points

(T2/P2)

Motor Rated Load Amps Per job data Motor Rated Line Voltage Per job data Motor Rated Line kW Per job data (if kW meter installed) Line Frequency 50 or 60 Hz Compressor Starter Type Reduced voltage or full? Stop-to-Start Timer Follow motor vendor recommenda-

NOTE:Other valuesareleft atthe defaultvalues. Thesemaybe changed by the operator as required. SERVICE2 and SERVICE3 tables can be modiﬁed by the owner/operator as required.

refrigerant temperature Is HGBP installed?

Per job data — See Modify Load Per job data — See Modify Load

tion for time between starts. See certiﬁed prints for correct value.

Points section Points section

Modify Minimum and Maximum Load Points (DT1/P1; D T2/P2) If Necessary —These pairs of chiller load points,

located on the SERVICE1table, determine when to limit guide vane travel or to open the hot gas bypass valve when surge prevention is needed. These points should be set based on individual chiller operating conditions.

If, after conﬁguring a value for these points, surge prevention is operating too soon or too late for conditions, these parameters should be changed by the operator.

Example of conﬁguration: Chiller operating parameters:

Refrigerant used: HFC-134a

Estimated Minimum Load Conditions:

44 F (6.7 C) LCW

45.5 F (7.5 C) ECW

43 F (6.1 C) Suction Temperature

70 F (21.1 C) Condensing Temperature

Estimated Maximum Load Conditions:

44 F (6.7 C) LCW

54 F (12.2 C) ECW

42 F (5.6 C) Suction Temperature

98 F (36.7 C) Condensing Temperature Calculate Maximum Load — Tocalculate the maximum load

points, use the design load condition data. If the chiller full load cooler temperature difference is more than 15° F (8.3° C), estimate the refrigerant suction and condensing temperatures at this difference. Use the proper saturated pressure and temperature for the particular refrigerant used.

Suction Temperature:

42 F (5.6 C) = 37 psig (255 kPa) saturated

refrigerant pressure (HFC-134a)

Condensing Temperature:

98 F (36.7 C) = 120 psig (1827 kPa) saturated

refrigerant pressure (HFC-134a)

Maximum Load DT2:

54 – 44 = 10° F (12.2 – 6.7 = 5.5° C)

Maximum Load DP2:

120 – 37 = 83 psid (827 – 255 = 572 kPad) To avoid unnecessary surge prevention, add about 10 psid

(70 kPad) to DP2 from these conditions:

DT2 = 10° F (5.5° C)

DP2 = 93 psid (642 kPad)

Calculate Minimum Load — Tocalculate the minimum load conditions, estimate the temperature difference that the cooler will have at 20% load, then estimate what the suction and condensing temperatures will be at this point. Use the proper saturated pressure and temperature for the particular refrigerant used.

Suction Temperature:

43 F (6.1 C) = 38 psig (262 kPa) saturated

refrigerant pressure (HFC-134a)

Condensing Temperature:

70 F (21.1 C) = 71 psig (490 kPa) saturated

refrigerant pressure (HFC-134a)

Minimum Load DT1 (at 20% Load):

2° F (1.1° C) Minimum Load DP1:

71 – 38 = 33 psid (490 – 262 = 228 kPad) Again, to avoid unnecessary surge prevention, add 20 psid

(140 kPad) at DP1 from these conditions:

DT1 = 2° F (1.1° C)

DP1 = 53 psid (368 kPad)

Page 56

If surge prevention occurs too soon or too late, make the following adjustments:

LOAD

At low loads

(,50%)

At high loads

(.50%)

SURGE PREVENTION SURGE PREVENTION

OCCURS TOO SOON OCCURS TOO LATE

Increase P1 by

10 psid (70 kPad)

Increase P2 by

10 psid (70 kPad)

Decrease P1 by

10 psid (70 kPad)

Decrease P2 by

10 psid (70 kPad)

MODIFY EQUIPMENT CONFIGURATION IF NECESSARY — The EQUIPMENT CONFIGURATION table has a number of screens to select, view, and/or modify. See Fig. 16 for the menu structure of this table. Carrier provides certiﬁed drawings that have the conﬁguration values required for speciﬁc jobsites. Modify these values only if requested.

CONFIG Screen Modiﬁcations — Change the values on this screen according to your job data. See certiﬁed drawings for the correct values. Modiﬁcations can include:

• chilled water reset

• entering chilled water control (Enable/Disable)

• 4 to 20 mA demand limit

• auto. restart option (Enable/Disable)

• remote contact option (Enable/Disable) LEAD/LAG Screen Modiﬁcations — Change the values on

this screen according to your job data. See certiﬁed drawings for speciﬁc values. Modiﬁcations can include:

• lead/lag selection

• load balance option

• common sensor option

• lag start/stop timers

• standby chiller option Owner-Modiﬁed CCN Tables—The following tables are de-

scribed for reference only. For detailed information on CCN operations, consult the CCN supplement for your chiller.

• OCCDEFCS Screen Modiﬁcations — This table contains the local and CCN time schedules, which can be modiﬁed here, or on the SCHEDULE screen as described previously.

• HOLIDEF Screen Modiﬁcations — This table conﬁgures the days of the year that holidays are in effect. See the holiday paragraphs in the Controls section for more details.

• BRODEF Screen Modiﬁcations — This table deﬁnes the outside-air temperature sensor and humidity sensor if one is to be installed. It also deﬁnes the start and end of daylight savings time. Enter the dates for the start and end of daylight savings, if required for your location. BRODEF also activates the Broadcast function, which enables the holiday periods deﬁned on the LID to take effect.

• Other Tables — The ALARMDEF, CONS-DEF, RUNTDEF, and WSMALMDF screens contain information for use with a CCN system. See the applicable CCN manual for more information on these screens. These screens can only be changed from a CCN Building Supervisor terminal.

CHECKVOLTAGESUPPLY—Access the STATUS 01 screen and read the LINE VOLTAGE: ACTUAL value. This reading should be equal to the incoming power to the starter. Use a voltmeter to check incoming power at the starter power leads. If the readings are not equal, an adjustment can be made by selecting the LINE VOLTAGE: ACTUAL parameter and then increasing or decreasing the value so that the value appearing on the LID is calibrated to match the incoming power voltage reading. Voltage can be calibrated only between 90 and 100% of the rated line voltage.

PERFORMAN AUTOMATED CONTROLTEST — Check the safety controls status by performing an automated controls test.Access the CONTROL TEST table from the SERVICE menu. This table has the following screens:

Automated Test As described above, a complete PSIO Thermistors Checks all PSIO thermistors only.

Options Thermistors Checks all options board thermistors. Transducers Checks all transducers. Guide Vane Actuator Checks the guide vane operation. Pumps Checks operation of pump output;

Discrete Outputs Activates all on/off outputs, all Pumpdown/Lockout Pumpdown prevents the low

Terminate Lockout Charges refrigerant and enables

FX Gear Oil Pump I/O Activates external gear main oil pump

control test.

either all pumps can be activated or individual pumps. Also tests the associated input such as ﬂow or pressure.

at once or individually. refrigerant alarm during

evacuation so refrigerant can be removed from the unit, locks the compressor off. and starts the water pumps.

the chiller to run after pumpdown lockout.

and auxiliary oil pump (if supplied).

Automated Test — Before running this test, be sure that the compressor is in the OFF mode and the 24-v input to the SMM is in range (per line voltage percent on STATUS01 screen). Put the compressor in OFF mode by pressing the STOP pushbutton on the LID.

The automated test starts with a check of the PSIO thermistors and proceeds through the rest of the tests listed in the table below. The test not only checks readings, such as temperature and pressure readings, but also lets the operator know if certain devices, such as pumps or relays, are on or off and if all outputs and inputs are functioning. It also sets the refrigerant type.

As each test is executed, the LID display shows which test is running as well as other pertinent data. At the end of each test, the LID displays, OK TO CONTINUE? If a test indicates a problem, error, or device malfunction, the operator can choose to address the problem as the test is being done or note the problem and proceed to the next test.

NOTE: If during the control test the guide vanes do not open, check to see that the low pressure alarm is not active. (This causes the guide vanes to close.)

NOTE: The oil pump test will not energize the oil pump if cooler pressure is below –5 psig (–35 kPa).

When the test is ﬁnished, or the EXIT

softkey is pressed,

the test stops and the CONTROL TEST menu is displayed. If a speciﬁc automated test procedure is not completed, access that test by scrolling to it and selecting it to test the function when ready. The CONTROL TEST menu is described in more detail in Table 8.

Check Pumpout System Controls and Optional Pumpout Compressor —

trols include an on/off switch, a 3-amp fuse, the compressor overloads, an internal thermostat, a compressor contactor, and a refrigerant high pressure cutout. The high pressure cutout is factory set to open at 161 psig (1110 kPa) and reset at 130 psig (896 kPa). Check that the water-cooled condenser has been connected. Loosen the compressor holddown bolts to allow free spring travel. Open the compressor suction and discharge service valves. Check that oil is visible in the compressor sight glass. Add oil if necessary.

The pumpout system con-

Page 57

Table 8 — Control Test Menu Functions

TESTS TO BE DEVICES TESTED

PERFORMED

1. Automated Tests* Operates the secondthrough seventh

2. PSIO Thermistors Entering chilled water

3. Options Thermistors Common chilled water supply sensor

4. Transducers Evaporator pressure

5. Guide Vane Actuator Open

6. Pumps All pumps or individual pumps may be

7. Discrete Outputs All outputs or individual outputs may

8. Pumpdown/Lockout When using pumpdown/lockout,

9. Terminate Lockout Starts pumps and monitors ﬂows.

10. FX Gear Oil Pump I/O

*During anyof the tests that arenot automated, an out-of-range read-

ing will have an asterisk (*) next to the reading and a message will be displayed.

†On open-drive chillers, differential pressure is the only oil pressure

displayed.

tests Leaving chilled water

Entering condenser water Leaving condenser water Discharge temperature Bearing temperature Motor winding temperature Oil sump temperature

Common chilled water return sensor Remote reset sensor Temperature sensor — Spare 1

Condenser pressure Oil pressure differential†

Close activated:

Oil pump — Conﬁrm pressure Chilled water pump — Conﬁrm ﬂow Condenserwater pump —Conﬁrm flow Auxiliary oil pump — conﬁrm

pressure† be energized:

Hot gas bypass relay Oil heater relay Motor cooling relay Tower fan relay Alarm relay Shunt trip relay

observe freeze up precautions when removing charge.

Instructs operator as to which valves to close and when.

Startschilled water and condenserwater pumps and conﬁrms ﬂows.

Monitors — Evaporator pressure

Turns pumps off after pumpdown. Locks out compressor.

Instructs operator as to which valves to open and when.

Monitors — Evaporator pressure

Terminates compressor lockout. Activates gear main oil pump; con-

ﬁrms pressure. Activatesoptionalgear auxiliary pump;

conﬁrms pressure.

Condenser pressure Evaporator temperature during pumpout procedures

Condenser pressure Evaporator temperature during charging process

Spare 2 Spare 3 Spare 4 Spare 5 Spare 6 Spare 7 Spare 8 Spare 9

See the Pumpout and Refrigerant Transfer Procedures (page 63) and Pumpout System Maintenance sections (page 83) for details on transferring refrigerant, oil speciﬁcations, etc.

HighAltitude Locations — Because the chiller is ini-

tially calibrated at sea level, it is necessary to recalibrate the pressure transducers if the chiller is to be operated at a high altitude location. Please see the calibration procedure in the Troubleshooting Guide section.

Charge Refrigerant into Chiller

The transfer, addition, or removal of refrigerant in spring isolated chillers may place severe stress on external piping if springs have not been blocked in both up and down directions.

The 17EX chiller may have the refrigerant already charged in the economizer/storage vessels. If chiller is not shipped fully charged, refrigerant is shipped separately to conform with transportation regulations. The 17EX may be ordered with a nitrogen holding charge of 15 psig (103 kPa). Evacuate the entire chiller, and charge chiller from refrigerant cylinders.

The full refrigerant charge on the 17EX will vary with chiller components and design conditions as indicated on the job data speciﬁcations. An approximate charge may be found in Physical Data and Wiring Schematics section, page 99. The full chiller charge is printed on the chiller identiﬁcation label.

Always operate the condenser and chilled water pumps during charging operations to prevent water in heat exchanger tubes from freezing.

Use the CONTROLS TEST terminate lockout function to monitor conditions and start the pumps.

If the chiller has been shipped with a holding charge, add refrigerant through the refrigerant charging valve (Fig. 6) or to the pumpout charging connection. First evacuate the nitrogen holding charge from the vessels. Charge the refrigerant as a gas until the system pressure exceeds 35 psig (141 kPa). After the chiller is beyond this pressure, the refrigerant should be charged as a liquid until all the recommended refrigerant charge has been added.

TRIMMING REFRIGERANT CHARGE — The 17EX is shipped with the correct charge for the design duty of the chiller.Trimming the charge can best be accomplished when the chiller is operating at design load. To trim, check the temperature differencebetween the leaving chilled water temperature and the cooler refrigerant temperature at full load design conditions. If necessary, add or remove refrigerant to bring the temperature difference to design conditions or a minimum differential.

INITIAL START-UP

Preparation—

1. Power is on to the main starter, oil pump relay (which

energizes both the compressor and gear oil pumps), tower fan starter, oil heater relay, and the chiller control center.

2. Cooling tower water is at proper level and at or below

design entering temperature.

Before starting the chiller,check that the:

Page 58

3. Chiller is charged with refrigerant and all refrigerant and all oil valves are in their proper operating position.

4. Gear oil, compressor oil, and motor bearing oil are at the proper levels in the reservoir sight glasses.

5. Compressor oil reservoir temperature is above 140 F (60 C) or refrigerant temperature plus 50° F (28° C).

6. Valves in the evaporator and condenser water circuits are open.

NOTE: If the water pumps are not automatic, make sure water is circulating properly.

7. Check the starter to be sure it is ready to start and that all safety circuits have been reset. Be sure to keep the starter door closed.

Do not permit water or brine that is warmer than 110 F (43 C) to ﬂow through the cooler or condenser. Refrigerant overpressure may discharge through the relief devices and result in the loss of refrigerant charge.

8. To prevent accidental start-ups, the CHILLER START/ STOP parameter is set to STOP at the factory.Access the STATUS01 screen and scroll to the CHILLER START/

STOP parameter. Press the RELEASE

softkey to enable

the chiller to start.

5. Check the main contactor for proper operation.

6. The PIC will activate an alarm for motor amps not sensed. Reset this alarm and continue with the initial start-up.

Check Motor Rotation

INITIAL MOTOR START-UP Initial Uncoupled Start-Up — The initial start-up of the mo-

tor should be made with the motor uncoupled. Verify that oil has been added to each bearing housing to the correct level.

1. If the motor is equipped with unidirectional fans (refer to the certiﬁed drawing) and veriﬁcation of rotation direction is required, do the following:

a. Start the motor and observe the rotation direction. See

Fig. 28.

b. Allow the motor to achieve full speed before discon-

necting it from the power source.

c. If the rotation direction must be changed, refer to the

Before Initial Start-Up, Motor Electrical Connection section, page 45. Otherwise, the motor can be restarted immediately after it has coasted to a stop.

Manual Operation of the Guide Vanes — Manual

operation of the guide vanes helps to establish a steady motor current when calibrating the motor amps value.

To manually operate the guide vanes, override the target guide vane position (TARGET GUIDE VANE POS param- eter on the STATUS01 screen). Manual control is also indicated on the default screen on the run status line.

1. Access the STATUS01 screen and look at the TARGET

GUIDE VANE POS parameter. (Refer to Fig. 13). If the compressor is off, the value reads zero.

2. Move the highlight bar to the TARGET GUIDE VANE

POS parameter and press the SELECT

3. Press ENTER

to override the automatic target. The screen

softkey.

reads a value of zero. The word SUPVSR! ﬂashes to indicate that manual control is in effect. The default screen also indicates that the guide vanes are in manual control.

4. To return the guide vanes to automatic mode, press the

SELECT

softkey; then press the RELEASE softkey.

After a few seconds, the word SUPVSR! disappears.

Dry Run to Test Start-Up Sequence

1. Disengage the main motor disconnect on the starter front

panel. This should only disconnect the motor power .Power to the controls, oil pumps, and starter control circuit should still be energized.

2. Look at the default screen on the LID. The status mes-

sage in the upper left corner should read, MANUALLY STOPPED. Press the CCN or LOCAL softkey to start. If MANUALLY STOPPED is not on the default screen

access the SCHEDULE screen and override the schedule or change the occupied time. Then, press the LOCAL

softkey to begin the start-up sequence.

3. Check that the chilled water and condenser water pumps

have energized.

4. Check that the oil pumps have started and have pressur-

ized the lubrication system. After the oil pumps have run about 15 seconds, the starter energizes and goes through its start-up sequence.

Fig. 28 — Correct Motor Rotation

2. After the initial start-up, monitor the bearing temperatures closely. Verify the free rotation of the oil rings on the sleeve bearings by observing them through the viewing port in the top of the housing. The rate of rise in bearing temperature is more indicative of impending trouble than the actual temperature. If the rate of rise in temperature is excessive or if the motor exhibits excessive vibration or noise, shut it down immediately and conduct a thorough investigation to ﬁnd the cause before operating the motor again. If the bearing temperatures rise and motor operation appears to be normal, continue operating the motor until the bearing temperatures stabilize.

The recommended limits on bearing temperature rise over ambient temperature are listed below:

Sleeve Bearing Temperature

As Measured By

A permanently installed

detector

A temporary detector on top

of the bearing sleeve near the oil ring

Temperature Rise

Over Ambient

Temperature

72° F (40° C)

63° F (35° C)

NOTE: When operating ﬂood-lubricated sleeve bearings, the bearing temperature must not be allowed to exceed 185 F (85 C) total temperature.

Page 59

Under normal conditions, for the self-lubricating bearing, the rate of temperature rise should be from 20° to 25° F (11° to 14° C) during the ﬁrst 10 minutes after starting up and approximately 40° F (22° C) over 30 minutes. The rate of bearing temperature rise is a function of the natural ventilation and operating conditions.

When the rate of bearing temperature rise is less than 2° F (1.1° C) per half-hour, the bearing temperature is considered to be stabilized.

If the total bearing temperature exceeds 195 F (91 C), the motor should be shut down immediately.

3. Any abnormal noise or vibration should be immediately investigated and corrected. Increased vibration (with the motor uncoupled from its load) can indicate a change in balance due to a mechanical failure or loose rotor part, a stator winding problem, a foundation problem, or a change in motor alignment.

4. Verify that the magnetic center indicator aligns with the shaft.

Initial Coupled Start-Up — After initial uncoupled start-up, take the following steps to ensure safe coupled operation:

1. Follow the procedure stated in the General Maintenance, ChillerAlignment section to align the motor to the driven chiller.

2. Prepare the coupling for operation according to the Disc Coupling Installation andAlignmentinstructions, this page. Note any match marks on the couplings and assemble accordingly. For sleeve bearing motors, verify that the correct limited end ﬂoat coupling has been installed. The end ﬂoat limits can be found on the certiﬁed drawing.

3. Ensure that all personnel are at a safe distance from rotating parts. Start the motor in accordance with instructions supplied with the motor control.

4. If the motor rotor fails to start turning in a second or two, shut off the power supply immediately. This can result from:

a. too low a voltage at the motor terminals b. the load is too much for the rotor to accelerate c. the load is frozen up mechanically d. all required electrical connections are not made e. single-phase power has been applied f. any combination of the above.

Investigate thoroughly and take corrective action before attempting a restart.

5. Carefully observe the vibration of the bearing housing and any abnormal noise generator. Note that coupled motor vibration may not be the same as uncoupled vibration amounts. If coupled vibration is excessive, recheck the mounting and alignment.

6. Carefully observe the bearing temperature rise and the movement of the oil ring.

If the bearing temperatures rise and motor operation appears normal, operation should continue until the bearing temperatures stabilize.

7. If possible, check the motor line currents for balance.

Note that each start time an induction motor starts, it is subjected to the full inrush of current along with heating of the stator and rotor windings. Each acceleration and repeated start can produce more heat than is produced and dissipated by the motor under full load. The starting duty for which the motor is designed is shown on a nameplate mounted on the motor. Do not exceed this amount if long motor life is expected.

Abnormally low terminal voltage, excessive load torque, and/or excessive load inertia during motor start-up can cause lengthened acceleration times during which rotor ventilation is reduced. This can cause rotor damage or can lead to shortened rotor life.

The temperature rating of the motor is shown on the main nameplate as a temperature rise above an ambient temperature. If there is a service factor, it is also shown. If the motor temperature switch opens, investigate the situation before attempting to continue operation.

If the motor is a TEWAC (Totally Enclosed Water-to-Air Cooled) design, the maximum inlet water temperature and the water ﬂow rate or gpm (gallons per minute) at the air cooler must be as shown on the certiﬁed drawing. Otherwise, the discharge air temperature from the cooler (actually the ambient air for the motor as shown by the main nameplate) could be too high for the motor to properly cool.

Disc Coupling Installation andAlignment — Be-

fore installing the disc coupling, inspect it for any signs of damage during shipment. Check that all parts are available, as ordered. Cradle or support the coupling components during handling to avoid damage. Wrap the components for protection. Keep ﬂanges free of nicks and burrs. Read all the instructions and review this procedure before beginning the actual installation. Some steps apply only to certain types of couplings (e.g., high speed coupling).

Use only the bolts and nuts supplied by the coupling manufacturer.

1. Installing the Coupling Hubs (Keyed Mounting).

a. Check the hub bore and shaft for nicks and burrs; dress

if necessary. b. For taper bores, check the ﬁt of the bore to the shaft. c. Fit keys precisely to the keyways in the shaft and hub.

Each key should have a tight ﬁt on the sides with a

slight clearance on top. To maintain dynamic balance,

the keys should ﬁll the keyways exactly and not be too

short or too long. d. Clean the hub bore and shaft. e. Heat the hub to expand the bore. DO NOT allow the

hub temperature to exceed 600 F (300 C). DO NOT

apply an open ﬂame to any part of the coupling. Car-

rier recommends using an oven to heat the hub.

To avoid the risk of explosion, ﬁre, or damage to the coupling and equipment and/or injury to personnel, do not use an open ﬂame or oil bath to expand the hub. If heat is used at anytime for installation, DO NOT ALLOW the hub temperature to exceed 600 F (300 C).

f. Place the hub in the proper position on the shaft. Hold

the hub in place as it cools. For tapered bores, verify the hub advance and install the shaft retaining nut.

Page 60

2. Offset and Angular Alignment — Reverse dial indication or optical methods of alignment (such as lasers) are recommended. A cold alignment and a hot check (with corrections, if necessary) are required. The hub ﬂange OD can be used to mount the alignment equipment and is machined to be concentric to the coupling bore. It can be used as the reference diameter.

3. FinalAssembly — The terminology used to identify parts and the order of assembly may differ from one coupling style to another. Follow the instructions that apply to the coupling you are installing.

High Speed Coupling (Spacer Style):

a. Place the spacer in position between the hub ﬂanges.

Place the disc packs between the ﬂanges on both ends of the coupling.

b. Insert the disc pack bolt into the reamed hole of the

hub and through the disc pack bushing. See Fig. 29 (compressor side). The ﬂat of the bolt head acts as a bolt lock with the hub body. Make sure the spacer is properly indexed for the large ﬂange holes to receive the bolt ends. Tap the bolts lightly for full engagement until the heads rest on the hub ﬂange surface. Repeat for the other bolts.

c. Place the spacing washers and disc pack nuts on the

bolts. Tightenall nuts evenly and in an alternating fashion to the torque speciﬁed in Table 9.

d. Place a spacing washer over a disc pack bolt. Insert

the bolt through the large hub ﬂange hole and the disc pack bushing. See Fig. 29 (gear side). Tap the bolts lightly for full engagement. Repeat for the other bolts.

e. Place the disc pack nuts on the bolts. Tighten all nuts

evenly and in an alternating fashion to the torque speciﬁed in Table 9.

Low Speed Coupling (Close-Coupled Style):

a. Place the disc pack and adapter in position over the

hub body diameter. The reamed holes in the adapter should be aligned with the large clearance holes in the hub as in the upper portion of Fig. 30. The large clearance holes in the adapter should be aligned with the reamed holes in the hub as shown in the lower portion of Fig. 30.

PACK

DISC PACK BOLT

HUB

MOTOR SIDE

FLANGE BOLT FLANGE NUT

ADAPTERSDISK

SPACING WASHER

DISC PACK NUT

GEAR SIDE

SHAFT PREPARATION (0.19 IN. [4.83 mm]

NOTES:

1. Compressor shaft should be in the thrust position and gear shaft

shouldbe on geometriccenter whencoupling is positionedas shown.

2. The taper is 1 inch per side for the driven unit bore (compressor

side).

Fig. 29 — Typical High Speed Coupling for 17FX

Compressor/External Gear (Spacer Style)

Table 9 — Disc Pack Nut Tightening Torques

Coupling

Size

204 1/2-20 55 75 45 60 304 5/8-18 115 155 90 120

*Light machine oil.

Nut

Size

Tightening

ft-lb

Torque

(dry)

N-m

Tightening

ft-lb

Torque

(lubed)*

N-M

NOTE: Motor rotor should be positioned on the mechanical center and gear shaft should be on geometric center when coupling is positioned as shown.

Fig. 30 — Typical Low Speed Coupling for 17FX

Compressor/External Gear (Close Coupled)

b. Loosely assemble the disc pack bolts, nuts, and spac-

ing washers. Half of the bolts attach the adapter to the disc pack. Refer to Fig. 30. These bolts are interspersed by bolts that attach the disc pack to the hub.

c. Tighten all nuts evenly and in an alternating fashion to

the torque speciﬁed in Table 9.

d. Bring the driving and driven equipment together until

the ﬂanges of the adapters just begin to touch. If there is a gap between the ﬂanges at any point, adjust the axial position of the equipment until the amount of gap is cut in half to minimize the amount of axial misalignment.

e. Rotate the equipment shafts until the ﬂange holes are

aligned.

f. Bolt the ﬂanges together using the ﬂange bolts and nuts.

See Fig. 30. Tighten all ﬂange nuts evenly and in a alternating fashion to the torque speciﬁed in Table 10.

Table 10 — Flange Nut Tightening Torques

(Low Speed Couplings Only)

Coupling

Size

304 5/16-24 20 27 18 24

*Light machine oil.

Nut

Size

Tightening

ft-lb

Torque

(dry)

N-m

Tightening

ft-lb

Torque

(lubed)*

N-M

Page 61

4. General Recommendations a. Both disc couplings are designed to operate for ex-

tended periods without the need for lubrication or maintenance. Visual inspection of the disc packs is enough to assess the operational condition of the coupling.

b. All machinery should be monitored to detect unusual

or changing vibration levels. Both couplings, under normal operating conditions, have no wearing parts and retain their original balance quality.Any change in vibration levels should be investigated, and remedial action should be taken immediately.

5. Removal a. Disassemble the coupling in the reverse order of the

applicable assembly procedure.

b. Keyed couplings — Install a puller on the hub using

the tapped holes provided in the hub face. Pull the hub off the shaft.

IMPORTANT INFORMATION:

Coupling guards protect personnel. ALL COUPLINGS MUST BE COVERED WITH A GUARD ACCORDING TO OSHA (Occupational Safety and Health Administration) REQUIREMENTS. Safety guards are included with this product and must be installed at all times.

1. Recheck alignment after all foundation bolts and mechanical connections are tightened.

2. Make sure all fasteners are properly installed and tightened.

3. Take the time to double check your work.

4. Only authorized disc coupling manufacturer replacement parts are to be used.

5. Call the disc coupling manufacturer for any clariﬁcations or questions.

The self-locking nuts on the disc pack bolts should be replaced after they have been assembled and removed from the bolts 5 times.

Check Oil Pressure and Compressor Stop

1. When the motor is up to full speed, note the differential compressor oil pressure reading on the LID default screen. It should be between 18 and 30 psid (124 to 206 kPad).

2. Press the Stop button and listen for any unusual sounds from the compressor as it coasts to a stop.

Calibrate Motor Current Demand Setting

1. Make sure that the MOTOR RATED LOAD AMPS parameter on the SERVICE1 screen has been conﬁgured. Place an ammeter on the line that passes through the motor load current transfer on the motor side of the power factor correction capacitors (if provided).

2. Start the compressor and establish a steady motor current value between 70% and 100% RLA by manually overriding the guide vane target value (TARGET GUIDE VANE POS parameter on the STATUS01 screen) and setting the chilled water set point (WATER/BRINE SETPOINT on the STATUS01 screen) to a low value. Do not exceed 105% of the nameplate RLA (rated load amps).

3. When a steady motor current value in the desired range is reached, compare the MOTOR RATED LOAD AMPS value on the STATUS01 screen to the actual amps shown on the ammeter on the starter. Adjust the amps value on the STATUS01 screen to match the actual value on the

starter ammeter, if there is a difference. Highlight the amps value; then, press the SELECT

INCREASE

to that indicated on the ammeter. Press ENTER the values are equal.

4. Release the target guide vane position to automatic mode. See the section on Manual Operation of the Guide Vanes, page 58, for instructions on how to do this.

or DECREASE softkey to bring the value

softkey. Press the

when

To Prevent Accidental Start-Up— The PIC can be

conﬁgured so that starting the unit is more difficult than just pressing the LOCAL

ice or whenever necessary. Access the STATUS01 screen, and highlight the CHILLER START/STOP param-

eter. Override the value by pressing SELECT

STOP

pears. When attempting to restart the chiller, remember to release the override. Access the STATUS01 screen and highlight CHILLER START/STOP. The 3 softkeys represent 3 choices:

• START - forces the chiller ON.

• STOP - forces the chiller OFF

• RELEASE - puts the chiller under remote or schedule

control.

RELEASE

additional information, see Local Start-Up, page 43. mand is in effect.

and ENTER softkeys. The word SUPVSR ap-

To return the chiller to normal control, press the

softkey; then, press the ENTER softkey. For

The default LID screen message indicates which com-

or CCN softkeys during chiller serv-

and then the

Hot Alignment Check — The operating temperatures

of various chiller components can affect the alignment of the compressor with the heat exchangers, gear, and driver. When all the chiller components have reached operating temperature (after running at nearly full load for 4 to 8 hours), make a hot alignment check.

Using proper equipment and procedures, make the hot alignment check with either assembled or disassembled couplings. The procedures are detailed in the General Maintenance section, page 67.

A clamping tool, Part No. TS-170, is available for checking alignment without disassembling the couplings. Check with your local Carrier representative.

Never operate the compressor or drive with the coupling guards removed. Serious injury can result from contact with rotating equipment.

Doweling — The size, quantity, and location of dowels

vary considerably with type and arrangement of gear and drive. Check your job data for speciﬁc doweling instructions. Typical doweling practices are described in the General Maintenance section.

Check Chiller Operating Condition — Check to

be sure that chiller temperatures, pressures, water ﬂows, and oil and refrigerant levels indicate that the system is functioning properly.

Page 62

Instruct the Operator — Check to be sure that the op-

erator(s) understands all operating and maintenance procedures. Point out the various chiller parts and explain their function as part of the complete system.

COOLER-CONDENSER — Relief devices, temperature sensor locations, pressure transducer locations, Schrader ﬁttings, waterboxes and tubes, and vents and drains.

ECONOMIZER/STORAGEVESSEL— Float chambers, relief valves, charging valve.

PUMPOUT SYSTEM — Transfer valves and pumpout system, refrigerant charging and pumpdown procedure, lubrication, and relief devices.

COMPRESSORASSEMBLY— Guide vane actuator, transmission, oil cooling system, temperature and pressure sensors, oil sight glasses, integral oil pump, isolatable oil ﬁlter, extra oil and motor temperature sensors, synthetic oil, and compressor serviceability.

COMPRESSOR LUBRICATION SYSTEM — Oil pump, cooler ﬁlter, oil heater, oil charge and speciﬁcation, operating and shutdown oil level, temperature and pressure, oil charging connections, and seal oil chambers.

EXTERNALGEAR LUBRICATION SYSTEM — Oil pump, cooler/ﬁlter,oil charge and speciﬁcation, operating and shutdown oil level, temperature and pressure, and oil charging procedures.

CONTROL SYSTEM — CCN and local start, reset, menu, softkey functions, LID operation, occupancy schedule, set points, safety controls, and auxiliary and optional controls.

AUXILIARYEQUIPMENT — Starters and disconnects, separate electrical sources, pumps, and cooling tower.

CHILLER CYCLES — Refrigerant, motor cooling, lubrication, and oil reclaim cycles.

MAINTENANCE — Scheduled, routine, and extended shutdowns; importance of a log sheet, water treatment, tube cleaning, and maintaining a leak-free chiller.

SAFETYDEVICESAND PROCEDURES — Electrical disconnects, relief device inspection, and handling refrigerant.

CHECK OPERATOR KNOWLEDGE — Start, stop,and shutdown procedures, safety and operating controls, refrigerant and oil charging, and job safety.

THIS MANUAL — Be sure that the operator is familiar with the contents of this manual.

OPERATING INSTRUCTIONS

Operator Duties

1. Become familiar withchiller refrigeration and related equipment before operating the chiller.

2. Prepare the system for start-up, start and stop the chiller, and place the system in a shutdown condition.

3. Maintain a log of operating conditions and document any abnormal readings.

4. Inspect the equipment, make routine adjustments, and perform a controls test. Maintain the proper oil and refrigerant levels.

5. Protect the system from damage during shutdown periods.

6. Maintain the set point, time schedules, and other PIC functions.

Prepare the Chillerfor Start-Up — Follow the steps

described in the Initial Start-Up section, page 57.

Starting the Chiller

1. Start the water pumps if they are not automatic.

2. On the LID default screen, press the LOCAL CCN

softkey to start the system. If the schedule indicates that the current time and date have been established as a run time and date (a condition referred to as ‘‘occupied’’) and the 3- and 15-minute start timers have expired, the start sequence will start. Follow the procedure described in the Start-Up/Shutdown/Recycle Sequence section, page 43.

Check the Running System — After the compres-

sor starts, monitor the LID display and observe the parameters for normal operating conditions:

1. The oil reservoir temperature should be above 150 F (66 C) or refrigerant temperature plus 70° F (38° C) during shutdown and above 125 F (52 C) during compressor operation.

2. The bearing oil temperature (BEARING TEMPERA- TURE on the STATUS01 screen) should be 150 to 200 F (65 to 93 C). If the bearing oil temperature reads more than 210 F (99 C) with the oil pump running, stop the chiller and determine the cause of the high temperature. Do not restart the chiller until corrected.

3. The oil level should be visible in the lower sight glass when the compressor is running. At shutdown, oil level should be halfway in the lower sight glass.

4. The oil pressure should be between 18 and 30 psid (124 to 207 kPad) differential, as seen on the LID default screen. Typically the reading will be 18 to 25 psid (124 to 172 kPad) at initial start-up.

5. The condenser pressure and temperature vary withthechiller design conditions. Typically the pressure ranges between 57 and 135 psig (393 and 930 kPa) with a corresponding temperature range of 60 to 105 F (15 to 41 C) for R-134a. The condenser entering water temperature should be controlled to remain below the speciﬁed design entering water temperature to save on compressor kilowatt requirements. The leaving condenser water temperature should be at least 20° F (11° C) above leaving chilled water temperature.

6. Cooler pressure and temperature also vary with the design conditions. Typical cooler pressure ranges between 30 and 40 psig (206 and 275 kPa); temperature ranges between 34 and 45 F (1 and 8 C) for R-134a).

7. The compressor may operate at full capacity for a short time after the pulldown ramping has ended, even though the building load is small. The active electrical demand setting can be overridden to limit the compressor IkW, or the pulldown rate can be decreased to avoid a high demand charge for the short period of high demand operation. Pulldown rate can be based on kW rate (LOAD PULLDOWN %/MIN) or temperature rate (TEMP PULLDOWN DEG/MIN) These parameters may be accessed on the CONFIG screen (see Table 2, Example 6).

8. The oil pump is energized once every 12 hours during shutdown periods to ensure that the shaft seal is ﬁlled with oil.

Stopping the Chiller

1. The occupancy schedule starts and stops the chiller automatically once the time schedule is set up.

2. Pressing the Stop button on the control panel for one second causes the alarm light to blink once to conﬁrm that the button has been pressed. Then, the compressor follows the normal shutdown sequence as described in the Controls section. The chiller is now in the OFF mode.

The chiller will not restart until the CCN

LOCAL

softkey is pressed.

Page 63

NOTE: If the chiller fails to stop, in addition to action that the PIC initiates, the operator should close the guide vanes by overriding the guide vane target to zero (to reduce chiller load) and then by opening the main disconnect. Do not attempt to stop the chiller by opening an isolating knife switch. High intensity arcing may occur. Do not restart the chiller until the problem is diagnosed and corrected.

After Limited Shutdown — No special preparations

should be necessary. Follow the regular preliminary checks and starting procedures. Control power must be maintained in order to keep the oil temperature hot and all control safeties operational. The oil pump operates occasionally to keep the contact seal ﬁlled with oil to prevent refrigerant loss.

ExtendedShutdown — The refrigerant should be trans-

ferred into the economizer/storage vessel (see Pumpout and Refrigerant Transfer Procedures, this page) in order to reduce chiller pressure and the possibility of leaks. Maintain a holding charge of 5 to 10 lbs (2.27 to 4.5 kg) of refrigerant within the cooler/condenser/compressor sections, to prevent air from leaking into the chiller.

If freezing temperatures are likely to occur in the chiller area, drain the chilled water, condenser water, and the pumpout condenser water circuits to avoid freeze-up. Keep the waterbox drains open.

Leave the oil charge in the chiller with the oil heater and controls energized to maintain the minimum oil reservoir temperature.

After Extended Shutdown — Be sure that the water

system drains are closed. It may be advisable to ﬂush the water circuits to remove any soft rust which may have formed. This is a good time to brush the tubes if necessary.

Check the cooler pressure on the LID default screen, and compare it to the original holding charge that was left in the chiller. If (after adjusting for ambient temperature changes) any loss in pressure is indicated, check for refrigerant leaks. See the Check Chiller Tightness section, page 46.

Recharge the chiller by transferring refrigerant from the economizer/storage vessel. Follow the Pumpout and Refrigerant Transfer Procedures section, this page. Observe

freeze-up precautions.

Carefully make all regular preliminary and running system checks. Perform a controls test before start-up. If the compressor oil level appears abnormally high, the oil may have absorbed refrigerant. Make sure that the oil temperature is above 150 F (66 C) or above the cooler refrigerant temperature plus 70° F (39° C).

Cold Weather Operation — When the entering con-

denser water temperature is very low, the PIC can automatically cycle the cooling tower fans off to keep the temperature up. Provide a way to control the condenser water temperature to the chiller either by arranging a tower bypass piping system and/or adding a tower water temperature control system.

Manual Guide Vane Operation — It is possible to

operate the guide vane manually in order to check control operations or control the guide vanes in an emergency. This is done by overriding the target guide vane position. Access the STATUS01 screen on the LID and highlight TARGET GUIDE VANE POS. To control the position, enter the desired percentage of guide vane opening. Zero percent is fully

closed; 100% is fully open. To release the guide vanes to automatic operation, press the RELEASE

NOTE: Manual guide vane control allows the operator to manipulate the guide vane position and override the pulldown rate during start-up. However, motor current above the electrical demand setting, capacity overrides, and chilled water temperature below the control point will override manual

softkey.

guide vane control and close the guide vanes, if necessary. For descriptions of capacity overrides and set points, see the Controls section.

Refrigeration Log — A refrigeration log, such as the

one shown in Fig. 31, is a convenient way to track routine inspection and maintenance and provides a continuous record of chiller performance. It is an aid in scheduling routine maintenance and in diagnosing chiller problems.

Keep a record of the chiller pressures, temperatures, and liquid levels on a log similar to Fig. 31. It is possible to automatically record PIC data by using CCN devices such as the Data Collection module and a Building Supervisor terminal. Contact your Carrier representative for more information.

PUMPOUT AND REFRIGERANT TRANSFER

PROCEDURES

Preparation —

an optional pumpout compressor.The refrigerant can be pumped for service work to either the cooler/condenser/compressor sections or the economizer/storage vessel by using the pumpout system. The following procedures describe how to transfer refrigerant from vessel to vessel and perform chiller evacuations.

To prevent tube freeze-up, always be sure that the condenser and cooler water pumps are operating whenever charging, transferring, or removing refrigerant from the chiller.

If the chiller water pumps are controlled by the PIC, access the CONTROL TEST table on the LID and use the PUMPDOWN/LOCKOUT screen or TERMINATE LOCKOUT screen to perform the functions described below. If the chiller water pumps are not controlled by the PIC, they must be turned on and off manually.

When performing pumpout, do not leave the compressor unattended for long periods of time or loss of compressor oil may result. Periodically check oil level.

The 17EX may come equipped with

Operating the Optional Pumpout Compressor

1. Be sure that the suction and the discharge service valves

on the optional pumpout compressor are open (back seated) during operation. Figure 32 shows the location of these valves (valves 2, 3, 4, 5, and 8). Rotate the valve stem fully counterclockwise to open. Front seating the valve closes the refrigerant line and opens the gage port to compressor pressure.

2. Make sure that the compressor holddown bolts have been

loosened to allow free spring travel.

3. Open therefrigerant inlet valve on the pumpout compressor.

4. Oil should be visible in the compressor sight glass under

all operating conditions and during shutdown. If oil is low, add oil as described under Pumpout System Maintenance section, page 83. The pumpout unit control wiring schematic is detailed in Fig. 33. The Optional Pumpout System is detailed in Fig. 34.

READING REFRIGERANT PRESSURES during pumpout or leak testing:

1. The LID display on the chiller control center is suitable

for determining refrigerant-side pressures and low (soft) vacuum. To measure evacuation or dehydration pressures, use a quality vacuum indicator or manometer to ensure the desired range and accuracy.This can be placed on the Schrader connections on each vessel by removing the pressure transducer.

Page 64

REFRIGERATION LOG CARRIER 17EX EXTERNALLY GEARED CENTRIFUGAL CHILLER

Plant

Chiller Serial No.

Chiller Model No. Refrigerant Type

REC. 1 REC. 2 REC. 3 REC. 4 REC. 5 REC. 6 REC. 7 REC. 8 REC. 9 TIME DATE OPERATOR INITIALS COOLER Refrigerant

Pressure Temperature

Water

Pressure In Pressure Out Pressure GPM Temperature In

Temperature Out CONDENSER Refrigerant

Pressure

Temperature Water

Pressure In

Pressure Out

Pressure GPM

Temperature In

Temperature Out COMPRESSOR Bearing Temperature Oil

Pressure Differential

Temperature (Reservoir)

Level Motor

FLA

Amps (or Vane Position) EXTERNAL GEAR Bearing Temperature Oil

Pressure Differential

Temperature (Reservoir)

Level Motor

FLA

Aps (or Vane Position

REMARKS: On an attached sheet, Indicate shutdowns on safety controls, repairs made, and oil or refrigerant added or removed. Include amounts. Include time, date, operator initials for each remark.

Fig. 31 — Refrigeration Log

Page 65

NOTE: Locationof pumpout compressor may varydepending on machine arrangement.

DRIVE END

COOLER ISOLATION VALVE

CHILLER

CHARGER VALVE

REAR VIEW

COMPRESSOR END

Fig. 32 — Pumpout Unit Location and Valve Number Locations

Page 66

COMPRESSOR MOTOR

Hz Ph Volts Max. RLA 50 3 400 4.7

3 298 10.9 3 230 9.5

3 460 4.7 3 375 3.8

Fig. 33 — Pumpout Unit Wiring Schematic

LEGEND

1—Compressor Motor 2—Control Circuit C—Contactor

OL — Compressor Overload RLA — Rated Load Amps

T’stat — Internal Thermostat

Circuit Disconnect Disconnect

Compressor Terminal Contactor Terminal

Overload Terminal Pumpout Unit Terminal

VENT VALVE

VALVES

CONDENSER WATER CONNECTIONS (FIELD PIPING)

CONDENSER DISCHARGE VALVE

CONTROL BOX (WIRING BY CONTRACTOR)

COMPRESSOR

Fig. 34 — Optional Pumpout Compressor

2. To determine economizer/storage vessel pressure, attach a 30 in.-0-400 psi (-101-0-2760 kPa) gage to the vessel.

3. Refer to Fig. 32 for valve locations and numbers.

Transfer, addition, or removal of refrigerant in springisolated chillers may place severe stress on external piping if springs have not been blocked in both up and down directions.

Transferring Refrigerant into the Economizer/ Storage Vessel —

moving refrigerant from the cooler/condenser/compressor sections into the economizer/storage vessel. This is normally done to prepare for service work on the cooler, condenser, or the compressor components or for long-term chiller shutdown.

These steps describe the method of

1. Isolate and push refrigerant into the economizer/storage vessel with the pumpout compressor. a. Valve positions: (Blank spaces indicate open valves).

VALVE 1 2 3 4 5 6 7 8 9 10 11 CONDITION CC CC C C

b. Turn off the chiller water pumps and pumpout con-

denser water.

c. Turn on pumpout compressor to push liquid out of the

cooler/condenser/compressor section.

d. When all liquid has been pushed into the economizer/

storage vessel, close the cooler isolation valve 7.

e. Access the CONTROL TEST table on the LID. Select

the PUMPDOWN/LOCKOUT screen. From this screen, turn on the chiller water pumps and view the chiller pressures.

f. Turn off pumpout compressor.

2. Evacuate refrigerant gas from the cooler/condenser/ compressor vessel.

a. Valve positions: close valves 2 and 5, open valves 3

and 4.

VALVE 1 2 3 4 5 6 7 8 9 10 11 CONDITION C C CCCC C

b. Turn on the pumpout condenser water. c. Run the pumpout compressor until the suction reaches

15 in. Hg (50 kPa abs). Monitor pressures on the LID

and on the refrigerant gages. d. Close valve 1. e. Turn off pumpout compressor. f. Close valves 3, 4, and 6. (All valves are now closed.) g. Turn off pumpout condenser water. h. Use the PUMPDOWN LOCKOUT screen on the LID

to turn off the chiller water pumps and to lock out the chiller compressor from operation.

Page 67

Transferring Refrigerant into the Cooler/ Condenser/CompressorSection —

scribe how to transfer refrigerant from the economizer/ storage vessel into the cooler/condenser/compressor section. This is normally done to prepare for service work on the economizer/storage vessel.

1. Isolate and push refrigerant into the cooler/condenser/ compressor section: a. Valve positions:

VALVE 1 2 3 4 5 6 7 8 9 10 11 CONDITION CCCCCC

b. Turn off chiller water pumps and pumpout condenser

water.

c. Turn on the pumpout compressor to push refrigerant

out of the economizer/storage vessel.

d. When all liquid refrigerant is out of the economizer/

storage vessel, close the cooler isolation valve 7.

e. Turn off the pumpout compressor.

2. Evacuate refrigerant from the economizer/storage vessel. a. Access the CONTROL TEST table on the LID. Select

the PUMPDOWN LOCKOUT screen. From this screen, turn on the chiller water pumps and monitor vessel pressures.

b. Valve positions: Close valves 3 and 4, open valves 2

and 5.

VALVE 1 2 3 4 5 6 7 8 9 10 11 CONDITION CC CCC C C

c. Turn on the pumpout condenser water. d. Run the pumpout compressor until the suction reaches

15 in. Hg (50 kPa abs). Monitor pressures on the LID

and on refrigerant gages. e. Close valve 6. f. Turn off the pumpout compressor. g. Close valves 1, 2, and 5 (all valves are now closed). h. Turn off the pumpout condenser water. i. From the CONTROL TEST table on the LID, turn off

the chiller water pumps and lock out the chiller compressor from operation.

These steps de-

Return Chiller to Normal Operating Conditions

1. Be sure that the vessel that was opened has been evacuated and dehydrated.

2. Access the CONTROL TEST table. From this table, select the TERMINATE LOCKOUT function to view the vessel pressures and to turn on chiller water pumps.

3. Open valves 1, 3, and 6.

VALVE 1234567891011 CONDITION CCCCCCCC

4. Slowly open valve 5, gradually increasing pressure in the evacuated vessel to 35 psig (141 kPa) for HFC-134a. Feed refrigerant slowly to prevent freeze-up.

5. Perform a leak test at 35 psig (141 kPa).

6. Open valve 5 fully. Let the vessel pressures equalize.

VALVE 1 2 3 4 5 6 7 8 9 10 11 CONDITION C C CCCC C

7. Open valves 9 and 10.

8. Open valve 7 to equalize liquid refrigerant levels.

9. Close valves 1, 3, 5, and 6.

VALVE 1234567891011 CONDITION CCCCCC C C

10. Continue to use the TERMINATE/LOCKOUT function on the LID to turn off water pumps and enable the compressor to operate.

GENERAL MAINTENANCE

Refrigerant Properties —

the standard refrigerant in the 17EX.At normal atmospheric pressure, HFC-134a boils at −14 F (−25 C) and must, therefore, be kept in pressurized containers or storage tanks. The refrigerant is practically odorless when mixed with air. This refrigerant is non-combustible at atmospheric pressure. Read the Material Safety Data Sheet (MSDS) and the latest ASHRAE Safety Guide for Mechanical Refrigeration to learn more about safe handling of this refrigerant.

Refrigerant HFC-134a will dissolve oil and some nonmetallic materials, dry the skin, and, in heavy concentrations, may displace enough oxygen to cause asphyxiation. When handling this refrigerant, protect the hands and eyes and avoid breathing fumes.

Refrigerant HFC-134a is

Adding Refrigerant — Follow the procedures de-

scribed in Charge Refrigerant into Chiller section, page 57.

Use the PUMPDOWN LOCKOUT function on the CONTROL TEST table to turn on the chiller water pumps and lock out the compressor when transferring refrigerant. Liquid refrigerant may ﬂash into a gas and cause possible freeze-up when the chiller pressure is below 30 psig (207 kPa) for HFC-134a. If the water pumps are not controlled by the PIC, they must be controlled manually.

Removing Refrigerant — When the optional pump-

out system is used, the 17EX refrigerant charge may be transferred into the economizer/storage vessel or another storage vessel. Follow procedures in the Pumpout and Refrigerant Transfer Procedures section when removing or transferring refrigerant.

Adjusting the Refrigerant Charge — If it is nec-

essary to add or remove refrigerant to improve chiller performance, follow theproceduresundertheTrimming Refrigerant Charge section.

Refrigerant Leak Testing — Because HFC-134a is

above atmospheric pressure at room temperature, leak testing can be performed with refrigerant in the chiller. Use an electronic detector, soap bubble solution, or ultra-sonic leak detector. To keep false readings to a minimum, be sure that the room is well ventilated and free from concentration of refrigerant. Before making any necessary repairs to a leak, transfer all refrigerant from the leaking vessel.

LeakRate — The ASHRAE recommendation is that chill-

ers should be immediately taken off line and repaired if the refrigerant leak rate for the entire chiller is more than 10% of the operating refrigerant charge per year.

Additionally,Carrier recommends that leaks totalling less than the above rate but more than a rate of 1 lb (0.5 kg) per year should be repaired during annual maintenance or whenever the refrigerant is pumped over for other service work.

Test After Service, Repair, or Major Leak — If

all refrigerant has been lost or if the chiller has been opened for service, the chiller or the affected vessels must be pressure and leak tested. Refer to the Leak Test Chiller section (page 46) to perform a leak test.

Page 68

Refrigerant HFC-134a MUST NOT be mixed with air or oxygen and pressurized for leak testing. In general, this refrigerant should not be allowed to be present with high concentrations of air or oxygen above atmospheric pressures, because the mixture can undergo combustion.

REFRIGERANT TRACER — Use an environmentally acceptable refrigerant as a tracer for leak test procedures.

TO PRESSURIZE WITH DRY NITROGEN — Another method of leak testing is to pressurize with nitrogen only and use a soap bubble solution or an ultrasonic leak detector to determine if leaks are present. This should only be done if all refrigerant has been evacuated from the vessel.

1. Connect a copper tube from the pressure regulator on the cylinder to the refrigerant charging valve. Never apply full cylinder pressure to the pressurizing line. Follow the listed sequence.

2. Open the charging valve fully.

3. Slowly open the cylinder regulating valve.

4. Observe the pressure gage on the chiller and close the regulating valve when the pressure reaches test level. Do not exceed 140 psi (965 kPa).

5. Close the charging valve on the chiller. Remove the copper tube if no longer required.

Repair the Leak, Retest, and Apply Standing Vacuum Test —

leaks with an electronic leak detector, soap bubble solution, or an ultrasonic leak detector. Bring the chiller back to atmospheric pressure, repair any leaks found, and retest.

After retesting and ﬁnding no leaks, apply a standing vacuum test, and then dehydrate the chiller. Refer to the Standing Vacuum Test and Chiller Dehydration in the Before Initial Start-Up section, page 49.

After pressurizing the chiller, test for

Checking Guide Vane Linkage — Refer to Fig. 35.

If slack develops in the drive chain, eliminate backlash as follows:

1. With the chiller shut down (guide vanes closed), remove

the chain guard, loosen the actuator holddown bolts, and remove the chain.

2. Loosen the vane sprocket set screw and rotate the sprocket

wheel until the set screw clears the existing spotting hole.

3. Withthe set screw still loose, replace the chain, and move

the vane actuator to the left until all the chain slack is taken up.

4. Tighten the actuator holddown bolts and retighten the set

screw in the new position.

5. Realign the chain guard as required to clear the chain.

Contact Seal Maintenance (Refer to Fig. 36) —

During chiller operation, oil thatlubricatesthesealseepsthrough the space between the contact sleeve (Item 18) and the lock nut (Item 15). This oil slowly accumulates in an atmospheric oil chamber and is automatically returned to the system by a seal oil return pump.

Oil should never leak around the outer diameter of the contact sleeve (Item 18). If oil is found in this area, O-ring (Item 12) should be checked and replaced.

The oil passing through the shaft seal carries with it some absorbed refrigerant. As the oil reaches the atmosphere, the absorbed refrigerant is released from the oil as a vapor. For this reason, a detector will indicate the presence of a slight amount of refrigerant around the compressor shaft whenever the chiller is running.

Fig. 35 — Electronic Vane Actuator Linkage

During shutdown, no refrigerant should be detected except for minute outgassing from residual oil in the seal area. There should be no oil seepage. If oil ﬂow or the presence of refrigerant is noted while the chiller is shut down, a seal defect is indicated. Arrange for a seal assembly inspection by a qualiﬁed serviceman to determine the cause of the leakage and make the necessary repairs.

SEAL DISASSEMBLY(Fig. 36) — Contact seal disassembly and repair should be performed only by well qualiﬁed compressor maintenance personnel. These disassembly instructions are included only as a convenient reference for the authorized serviceman.

For ease of disassembly, refer to Fig. 36 while following these instructions.

1. Remove refrigerant.

2. Remove compressor shaft coupling hub and coupling spacer (if any).

3. The snap ring (Item 16) used forsealassembly/disassembly is clipped over three screws (Item 41) on the windage baffle (Item 7). Remove the snap ring and put it aside for now.

4. Remove the screws holding the windage baffle and the shaft end labyrinth (Item 8).

5. Remove the contact sleeve key (Item 11).

6. Using a snap ring tool, install the snap ring (Item 16) in the groove on the end of the contact sleeve (Item 18), as shown in Fig. 36.

7. Remove the tubing between the coupling (Item 20) and the atmospheric oil chamber. Loosen the bolts (Item 6) holding the coupling guard mounting ring (Item 4) and the seal housing (Item 3). The spring contact sleeve (Item 17) will push the housing out until the snap ring (Item 16) contacts the seal housing (Item 3). To avoid binding, loosen the bolts in a circular pattern until the spring stops pushing out on the housing. Then, remove 2 bolts that are 180 degrees apart. Replace them with a 1/2-13 all-thread rod to support the housing while the rest of the bolts are removed.

8. Remove the rest of the bolts, and remove the seal housing.

Page 69

LEGEND

1—Lubricating Tube 2A — O-Ring 2B — O-Ring 3—Seal Housing 4—Coupling Guard Mounting Ring 5—Plain 6—Hex Head Bolt, 7—Windage Baffle 8—Shaft End Labyrinth 9—Screw 10 — Screw, 10-24 × 11 — Key, Contact Sleeve 12 — O-Ring 13 — Compressor Shaft 14 — O-Ring 15 — Lock Nut 16 — Snap Ring (Service tool only; must be removed for operation) 17 — Spring Contact Sleeve 18 — Contact Sleeve 19 — Outer Carbon Ring 20 — Coupling (Connection to atmospheric oil chamber) 21 — Rotating Contact Ring 22 — Diaphragm Retainer 23 — Inner Seal Retaining Screw, 10-24×1lg(14Required) 24 — Gasket 25 — Diaphragm 26 — Inner Carbon Ring 27 — Inner Seal Spring 28 — Inner Seal Retainer 29 — Seal Gland Sleeve 30 — Spacer 31 — Journal Bearing Housing 32 — Journal Bearing 33 — Inner Seal Shim 34 — Inner Carbon Guide Ring 35 — O-Ring 36 — Inner Carbon Key 37 — Screw, 10-24 × 1 38 — Retaining Ring 39 — Seal Shoulder 40 — Compressor End Wall 41 — Thread Cut Screw, 8-32 × 42 — Screw,

⁄2-in. Washer (8 Required)

⁄2-13×4lg(8Required)

⁄4-20×3⁄4lg (4 Required)

⁄2lg

⁄4lg (2 Required)

⁄16-18×13⁄4lg (2 Required)

⁄4lg (3 Required)

Fig. 36 — Contact Seal

NOTE: Adjust shims (Item 33) to maintain .525 ± .01 in. (13.3 ± .3 mm) dimensionwith shaftthrust toward driveand check carbon for +.06 minimum travel.

Page 70

9. Place a clean, lint-free cloth on a smooth, sturdy work surface. Place the seal housing assembly on the cloth with the face of the contact sleeve in contact with the cloth. While one person pushes down on the housing to compress the spring, another person must remove the snap ring. Then, slowly let the seal housing rise until the spring is fully extended.

10. Remove Items 2B and 12 (O-rings).

11. Slide the outer carbon ring (Item 19) off the shaft.

12. Remove the lubricating tube (Item 1) and gasket (Item 24).

13. Remove the inner carbon key (Item 36).

14. Remove the inner seal retaining screws (Item 23) and the diaphragm retainer (Item 22).

15. Using a spanner wrench, loosen the lock nut (Item 15). The lock nut has a right-hand thread. Remove the lock nut. The inner seal spring (Item 27) may push the contact ring part way out as the lock nut is loosened.

16. Carefully slide the rotating contact ring (Item 21) off the shaft. The ring slips onto the shaft with a very close tolerance and is prone to sticking. Slide it slowly to avoid a tight jam. To release, tap gently with a SOFT hammer.

17. Remove O-ring (Item 14). This O-ring will be crushed into a triangular shape. Since it is not an ordinary O-ring gland, this is normal.Always replace with a new O-ring.

18. The seal gland sleeve (Item 29) can be removed, but it is generally not necessary to do so. If the seal gland is removed, make sure it is reinstalled with the bevel (that contains the O-ring) facing outward.

19. The inner carbon ring (Item 26), the diaphragm (Item 25), the inner carbon guide ring (Item 34), and the inner seal spring (Item 27) can be removed as an assembly.The carbon ring is held to the guide ring by raised barbs on the guide ring. Carefully pull the carbon ring from the guide ring. The diaphragm can now be removed from the guide ring. Inspect the diaphragm for wear.

20. To remove the inner seal retainer (Item 28) and O-ring (Item 35), use 4 screws (Item 23) in the 4 threaded holes spaced evenly around the seal retainer to jack the part out of position.

If the inner seal shims are damaged, carefully measure them so that a shim package of the same thickness can be installed.Thethicknessof the shim package should not be changed unless the compressor shaft and/or thrust bearing are replaced. Replacing either of these items could affect the ﬂoat of the inner seal. This ﬂoat is adjusted by varying the thickness of the shim pack.

This completes the disassembly of the seal.

Clean all parts to be reused with solvent, coat with oil and place in a protected area until needed.

SEAL REASSEMBLY (Fig. 36) — Be sure that all gasket surfaces are clean and that all holes, including oil holes, are properly aligned between the gasket and mating ﬂange. Coat the gasket with oil-graphite mixture to prevent sticking.

1. Install the inner seal retainer (Item 28) and O-ring (Item 35). Then, remove the bolts to allow installation of the inner seal assembly.

2. Replace the seal gland sleeve (Item 29) if it has been removed. Make sure that the plain side is against the shaft shoulder and that the beveled side is facing outward.

NOTE: If the seal gland sleeve is oriented improperly, refrigerant will leak under the contact ring.

3. Place the diaphragm (Item 25) over the inner seal retainer (Item 28). Withthe best lapped sealing face of the carbon away from the diaphragm and the notch for the key centered between two of the bolt holes in the diaphragm, gently push the inner carbon ring (Item 26) into the inner carbon guide ring until it is tight against the diaphragm. Make sure that the diaphragm is not wrinkled or folded between the carbon and the retainer. Place the spring (Item 27) over the back of the guide ring. Place this assembly into the seal, and make sure that the carbon face can travel a minimum of 0.06 inches (1.5 mm) in each direction from the outside edge of the seal gland sleeve (Item 29).

4. Install the O-ring (Item 14). Slide the rotating contact ring (Item 21) into position against the seal gland sleeve. Install the lock nut (Item 15) and tighten it with a spanner.

5. Gently rotate the inner seal assembly to line up the bolt holes in the diaphragm with the bolt holes in the inner seal retainer (Item 28). Place the diaphragm retainer over the diaphragm with the beveled side toward the diaphragm. Install the 14 one-inch long screws (Item 23), leaving the top 2 holes on either side of the notch in the carbon open. Tighten to 2 ft-lb.

6. Install the inner carbon key (Item 36) using the 1-1/4-in. screws (Item 37). Tighten to 2 ft-lb.

7. Install the lubricating tube (Item 1) and gasket (Item 24).

8. Lightly coat the outer carbon ring with compressor oil. Then, slide the outer carbon ring (Item 19) into position against the rotating contact ring.

9. Install O-ring (Item 12).

10. Place the contact sleeve (Item 18) face down on a clean, lint-free cloth on a smooth, hard, work surface, and place the contact sleeve spring over the sleeve. Lightly coat the outside surface of the contact sleeve with compressor oil. While one person places the seal housing (Item 3) over the contact sleeve and presses the spring down, another person must install the snap ring (Item 16) in the groove around the small end of the contact sleeve. Once the snap ring is ﬁrmly seated in the groove, slowly let the seal housing rise until the snap ring rests against the housing. Rotate the sleeve in the seal housing until the key slot in the sleeve is in line with the bolt hole for the contact sleeve key (Item 11).

11. Install the O-ring (Item 2B) into its groove, and place the seal housing into position on the compressor. Guide rods can help accomplish this task. Place the coupling guard mounting ring (Item 4) over the seal housing, and fasten both in place with 8 hex-head bolts (Item 6). Draw in the housing against the seal spring by tightening the bolts in steps in a crisscross pattern to draw the housing evenly.

12. Once the bolts have been tightened, remove the snap ring from the contact sleeve, and set it aside.

13. Install the contact sleeve key (Item 11).

14. Install the shaft end labyrinth (Item 8) and the windage baffle using screws (Item 9). The split lines of the labyrinth and windage baffle should be located 90 degrees apart.

15. Mount the snap ring (Item 16) on the screws (Item 41) near the inside surface of the windage baffle.

16. Reconnect the tubing from the atmospheric oil chamber to the coupling (Item 20).

The reassembly of the seal is complete. Run the oil pump to ﬁll the seal, and rotate the shaft sev-

eral times by hand before leak testing.

Page 71

Chiller Alignment

ALIGNMENT METHODS — There are several established procedures for aligning shafts. The dial indicator method is presented here since it is considered to be one of the most accurate and reliable. Another faster and easier method for alignment involves using laser alignment tools and computers. Follow the laser tool manufacturer’s guidelines when using the laser technique.

Where job conditions such as close-spaced shafts prohibit the use of dial indicators for coupling face readings, other instruments such as a taper gage may be used. The same procedures described for the dial indicator may be used with the taper gage.

Shafts placed in perfect alignment in the non-operating (cold) condition will always move out of alignment to some extent as the chiller warms to operating temperature. In most cases, this shaft misalignment is acceptable for the initial run-in period before hot check and alignment can be made (see Hot Alignment Check section, page 61).

NOTE: The physical conﬁguration of the 17FX compressor makes the oil sump temperature a more signiﬁcant factor in alignment than the suction and discharge temperatures. Therefore, warm the sump oil to operating temperature (approximately 140 F [60 C]), if possible, before beginning alignment procedures.

General

1. Final shaft alignment must be within .002-in. (.05-mm)

TIR (Total Indicated Runout) in parallel. Angular alignment must be within 0.00033 inches per inch of traverse (0.00033 mm per mm of traverse) across the coupling face (or inch of indicator swing diameter) at operating tem- peratures. For example, if a bracket-mounted indicator moves through a 10-in. diameter circle when measuring angular misalignment, the allowable dial movement will be 10 times 0.00033 for a total of 0.0033 in. (0.0033 mm).

2. Follow the alignment sequence speciﬁed in the Near

Final Alignment section.

3. All alignment work is performed on gear and drive equip-

ment. Once the compressor is bolted in a perfectly level position and is piped to the cooler and condenser, it must not be moved prior to hot check.

4. All alignment checks must be made with the equipment

hold-down bolts tightened.

5. In setting dial indicators on zero and when taking read-

ings, both shafts should be tight against their respective thrust bearings.

6. The space between coupling hub faces must be held to

the dimensions in Fig. 29 and 30.

7. Accept only repeatable readings. High Speed Coupling Alignment

1. Move the gear with the coupling attached into alignment

with the compressor coupling. The compressor must be in the thrust position and the gear must be centered between the thrust collars when determining gear position relative to the compressor.Adjust the jackscrews to reach close alignment. Follow the procedures outlined in the Correcting Angular Misalignment and Correcting Parallel Misalignment sections.

2. A 5-in. long spacer hub is supplied between the gear and

compressor.Maintain the exact hub-to-hub distance speciﬁed in Fig. 29.

3. Where the shaft ends are very close, a taper gage may be

used in place of the dial indicator.

4. Get the gear alignment as close as possible by using the

jackscrew adjustment.

Low Speed Coupling Alignment

1. Move the motor with the coupling attached into alignment with the gear coupling. The motor must be in its mechanical center and the gear must be centered between the thrust collars when determining the motor position relative to the gear. Adjust the jackscrews to reach close alignment. Follow the procedure outlined in the Correcting Angular Misalignment and Correcting Parallel Misalignment sections.

2. Maintain the exact hub-to-hub distance as speciﬁed in Fig. 30.

3. Where the shaft ends are very close, a taper gage may be used in place of the dial indicator.

4. Get the motor alignment as close as possible by using the jackscrew adjustment.

NOTE: The drive shaft end-ﬂoat at ﬁnal drive position must not allow the coupling hub faces to make contact or the coupling shroud to bind.

PRELIMINARYALIGNMENT — To get within dial indicator range, roughly align the equipment as shown in Fig. 37 and as described below.

Place a straight edge across the OD of one coupling to the OD of the other. Measure the gap between the straight edge and the OD of the second coupling with a feeler gage. Then, by adding or removing shims at each corner, raise or lower the equipment by the measured amount.

In a similar manner, measure the shaft offset from side to side and jack the equipment over as required to correct.

Fig. 37 — Checking Preliminary Alignment

NEAR FINAL ALIGNMENT — Once the chiller components are within dial indicator range, the adjustments for misalignment should be made in a speciﬁc sequence. The four positions of alignment described below are arranged in the recommended order.

1. Angular in elevation — This alignment is adjusted with shims and is not readily lost in making the other adjustments.

Page 72

2. Parallel in elevation — This alignment is also made with shims, but it cannot be made while there is angular misalignment in elevation.

3. Angular in plan — This position can easily be lost if placed ahead of the two adjustments in elevation.

4. Parallel in plan — This adjustment cannot be made while there is still angular misalignment in plan and can easily be lost if elevation adjustments are made.

Correcting Angular Misalignment Preparation — Shaft angular misalignment is measured on

the face of the coupling hubs or on brackets attached to each shaft (see Fig. 38 and 39). Brackets are preferred since they extend the diameter of the face readings.

Attach a dial indicator to one coupling hub or shaft and place the indicator button against the face of the opposite hub. Position the indicator so that the plunger is at approximately mid-position when the dial is set to zero. Both shafts should be held tightly against their thrust bearings when the dial is set and when readings are taken.

To be sure that the indicator linkage is tight and the button is on securely, rotate the coupling exactly 360 degrees. The dial reading should return to zero. Accept only repeatable readings.

Fig. 38 — Measuring Angular Misalignment

in Elevation

Fig. 39 — Measuring Angular Misalignment

in Elevation Using Brackets

Measurement— Occasionally,coupling faces may not be perfectly true or may have been damaged in handling. To compensate for any such runout, determine the actual or ‘‘net’’ shaft misalignment as follows:

Check the opening at the top and at the bottom of the coupling faces (or at each side when making plan adjustment). Rotate both shafts exactly 180 degrees and recheck the openings. Record the difference. (Example below is in inches.)

Page 73

If the larger opening remains the same but changes from side to side, the shafts are in perfect alignment. The change in opening is due entirely to coupling runout, as above, or to a burr or other damage to the coupling face.

If the larger opening remains the same, and remains on the same side, the amount is entirely shaft (net) misalignment.

If the larger opening remains on the same side but changes amount, misalignment and runout are present. Add the two amounts and then divide by two to get the actual or net misalignment.

Obtain:

D — coupling face diameter in inches (or indicator but-

ton circle)

L — distance between front and rear holddown bolts

(inches)

M — net misalignment in inches

And:

Divide L, the bolt distance, by D, the coupling diameter. Multiply the result by M, the net misalignment.

S= × M

Example: Face diameter 5 in. (D). Distance between front

and rear holddown bolts 30 in. (L). Net misalignment in elevation .012 in. (M).

30 divided by 5 is 6 6 multiplied by .012 is .072 in. S = .072 in.

If the larger opening between coupling faces is at the top, place .072 in. of shim under each rear foot or remove .072 in. from the front footings to bring the couplings into angular alignment in elevation.

Tighten the holddown bolts and recheck the net misalignment.

The height of the shaft above the footings and the distance the shaft extends beyond the equipment will not affect the calculations.

Determine the angular adjustment in plan by the same method of calculation. At this point, however, the procedure should include a correction for the change in coupling gap which always occurs in adjusting angular alignment (Fig. 40). By selecting the proper pivot point (see Fig. 41), the coupling gap can be kept at the dimension speciﬁed in the job data.

1. Pivot on the front bolt at the closed side of the couplings

to shorten the gap; pivot on the front bolt at the open side to lengthen it. It may sometimes be advantageous to pivot half the required amount on one front footing and half on the other.

2. Place a dial indicator against the rear foot as indicated in

Fig. 41.

3. Place a screw jack on the other rear foot to move the equip-

ment towards the indicator.

If the larger opening changes amount and also changes from side to side, subtract the smaller amount from the larger and divide by two to obtain the net misalignment.

Adjustment — Having obtained the net misalignment, the amount by which the equipment must be moved can now be calculated.

To determine:

S — amount of movement (in plan) or the thickness of

shim (in elevation) required.

S—Thickness of Shim Required L—Distance Between Front and

Rear Holddown Bolt in Inches

D—Diameter of Coupling in Inches M—Net Misalignment in Inches

Fig. 40 — Alignment Formula

Page 74

4. Loosen all holddown bolts except the pivot bolt. Turn the screw jack until the rear end of the equipment moves against the indicator by the desired amount.

5. Tighten the holddown bolts and recheck the indicator. If the reading has changed, loosen the three bolts and readjust. It may be necessary to over or undershoot the desired reading to allow for the effect of bolt tightening.

Fig. 41 — Adjusting Angular Misalignment in Plan

Correcting Parallel Misalignment Preparation — Attach the dial indicator to one shaft or cou-

pling hub and place the indicator button on the outside diameter of the other hub. The reach of the dial from one hub to the other should be parallel to the shafts, and the dial button shaft should point directly through the center of the shaft on which it rests. Compress the plunger to about midposition and set the dial at zero.

Check the tightness of the dial button and the indicator linkage by rotating the shaft to which the indicator is attached 360 degrees. The dial should return to zero. Check for repeatability.

Check for runout by rotating the hub on which the dial button rests 180 degrees. If the runout exceeds .001 total indicator reading, the hub should be removed and the shaft checked. Shaft runout must not exceed .001 TIR.

The effect of hub runout can be eliminated by locating a position on the half coupling where two readings 180 degrees apart read zero. Rotate the coupling so that one zero point is at the top and the other at the bottom when checking for misalignment in elevation. Place the zero points side to side in a similar manner when checking for misalignment in plan.

Measurement — With dial set at zero in the top position, rotate the shaft to which the indicator is attached 180 degrees. If the dial reading is plus, the shaft on which the button rests is low. If the reading is minus, the shaft on which the button rests is high.

Never accept a single reading. Look for repeatability. Rotate the shaft several times to see if the reading remains the same. It is good practice to reverse the procedure and read from zero at the bottom.

Always rotate the shafts in the same direction when taking readings. Backlash in the coupling teeth could cause some differences.

Adjustment — Divide the total indicator reading by two to obtain the exact amount of shaft offset. As illustrated in Fig. 42, the indicator will read the total of A plus B but the required shaft adjustment is only half of this as indicated by C.

Add or remove identical amounts of shims at all footings to bring the shaft to the proper elevation. Tighten all the holddown bolts and recheck the readings. Parallel alignment must be within .002 TIR.

To correct parallel misalignment in plan, use a screw jack and dial indicator as shown in Fig. 42. With a front holddown bolt as the pivot, move the rear of the equipment over. Then, with the rear holddown bolt on the same side acting as the pivot, move the front end of the equipment over by the same amount.

FINAL ALIGNMENT — The procedures and tolerance requirements for ﬁnal alignment are the same as those described in the Near Final Alignment section. Final alignment is performed just prior to grouting and chiller hot check. All piping, including water and steam, must be completed, but the water and refrigerant charges need not be in place.

HOT ALIGNMENT CHECK General — When all chiller components have reached op-

erating temperature (after running near full load for from 4 to 8 hours), a hot alignment check must be made. Hot alignment check may be made with couplings assembled or disassembled.

Disassembled Couplings

1. Shut down chiller.

2. With chiller hot, quickly disassemble couplings.

3. Check angular and parallel alignment in plan and eleva-

tion as described in the Near Final Adjustment section. Record the indicator readings (see page CL-12) and make necessary adjustments to bring alignment within .002 in. TIR and .00033 inches per in. of coupling face traverse (or in. of indicator swing). Follow procedures described in the Near Final Alignment section.

4. Reinstall couplings and run chiller until it again reaches

operating temperature.

5. Repeat steps 1 through 4 until alignment remains within

speciﬁed tolerances.

Assembled Couplings — If there is room on the shaft between coupling and component to clamp a sturdy bracket, the arrangement illustrated in Fig. 43 maybe used. The clamps must have room to rotate with the shaft.

This method is quicker because the couplings do not have to be disassembled. In addition, eccentricity or coupling face runout are not problems since both shafts rotate together.

Page 75

Fig. 42 — Correcting Parallel Misalignment

When using brackets, the diameter in the alignment formula (see Near Final Alignment, Connecting Angular Misalignment section) will be that of the circle through which the dial indicator rotates.

1. Shut down the chiller.

2. With chiller at operating temperature, quickly install

brackets.

3. Check that alignment is within .002 in. TIR and

.00033 in. per in. of traverse (0.00033 mm per mm of traverse) across the diameter of measurement. Adjust alignment as required. (Refer to Near Final Alignment section.)

4. Remove brackets and run chiller until operating tempera-

ture is again reached.

Fig. 43 —Alignment Check —Assembled Coupling

5. Recheck the alignment per steps 1 through 4 until it remains within the speciﬁed tolerances.

Be surethatcoupling guardsare replaced after these checks.

DOWELING Techniques — After a hot alignment check has been com-

pleted, the compressor, gear and drive must be doweled to their sole plates. Doweling permits exact repositioning of components if they have to be moved.

1. Doweling must be completed with equipment at maximum operating temperature (full load).

2. Use No. 8 taper dowels to dowel the compressor, gear, and drive to the base. Use a

⁄32-in. drill and No. 8 taper reamer with straight ﬂutes. Drill pilot hole and then expand the pilot hole to ﬁnal dimension.

3. Fit dowel so that

⁄16-in. of taper is left above the equipment foot. If dowel holes are re-reamed as a result of realignment, be sure dowels are tight and do not bottom.

4. Place dowels as nearly vertical as possible.

5. Coat the dowels with white lead or other lubricant to prevent rusting.

6. Tap dowel lightly into position with a small machinist’s hammer. A ringing sound will indicate proper seating.

Dowel the suction end of the compressor base, the two feet at the high speed end of the gear, and the drive feet in accordance with the drive manufacturer’s instructions. The number of dowels used in the drive is usually four, but some manufacturers require more.

Page 76

WEEKLY MAINTENANCE

Check the Lubrication System —

on the compressor reservoir sight glass, and observe the level each week while the chiller is shut down.

If the level goes below the lower sight glass, the oil reclaim system will need to be checked for proper operation. If additional oil is required, add oil as follows:

Oil may be added through the oil drain and charging valve (Fig. 2, Item 22) using a pump. However, an oil charging elbow on the seal-oil return chamber (Fig. 4) allows oil to be added without pumping. The seal oil return pump automatically transfers the oil to the main oil reservoir. A pump is required for adding oil against refrigerant pressure. The oil charge is approximately 20 gallons (76 L) for FX (size 531-

599) style compressors. The added oil must meet Carrier’s speciﬁcations. Refer to Changing theOilFiltersandOilChanges sections. Any additional oil that is added should be logged by noting the amount and date. Any oil that is added due to oil loss that is not related to service will eventually return to the sump, and must be removed when the level is high.

An oil heater is controlled by the PIC to maintain oil temperature above 150 F (65.5 C) or refrigerant temperature plus 70° F (38.9° C) (see the Controls section) when the compressor is off. The LID STATUS02 screen displays whether the heater is energized or not (OIL HEATER RELAY). If the PIC shows that the heater is ON, but the sump is not heating up, the power to the oil heater may be off or the oil level may be too low. Check the oil level, the oil heater contactor voltage, and oil heater resistance.

The PIC does not permit compressor start-up if the oil temperature is too low. The PIC continues with start-up only after the temperature is within limits.

After the initial start or a 3-hour power failure, the PIC allows the chiller to start once the oil is up to proper temperature, but uses a slow ramp load rate of 2° F (1.6° C) per minute.

Be sure that the isolation valves on the oil line near the ﬁlter(s) (Fig. 44) are fully open before operating the compressor.

There are no lubrication requirements for the FX disc coupling.

Check the oil level in the gear reservoir and observe the level each week. If additional oil is required, add oil as described in the Oil Changes section on page 77. The added oil must meet Carrier speciﬁcations. (SeeTable 11.)Do not overﬁll the reservoir.Any additional oil added or removed should be logged by noting the amount and date.

Mark the oil level

Check the oil level in the motor bearings and observe the level each week. If additional oil is required, add oil as described in the Oil Changes section on page 77. The added oil must meet Carrier speciﬁcations. (See Table 11.) Any additional oil added or removed should be logged by noting the amount and date.

SCHEDULED MAINTENANCE

Establish a regular maintenance schedule based on the actual chiller requirements such as chiller load, run hours, and water quality. The time intervals listed in this section are offered as guides to service only.

Service Ontime — The LID displays a SERVICE ON-

TIME value on the STATUS01 screen. This value should

be reset to zero by the service person or the operator each time major service work is completed so that time span between service can be tracked and viewed.

Inspect the Control Center — Maintenance is lim-

ited to general cleaning and tightening of connections. Vacuum the cabinet to eliminate dust build-up. If the chiller controls malfunction, refer to the Troubleshooting Guide section for control checks and adjustments.

Be sure power to the control center is off when cleaning and tightening connections inside the control center.

Check Safety and Operating Controls Monthly

To ensure chiller protection, the automated control test

—

should be done at least once per month. SeeTable 3 for safety control settings.

Changing the Oil Filters

COMPRESSOR OIL FILTER — Change this oil ﬁlter annually or whenever the chiller is open for repairs. The 17FX compressor has an isolatable ﬁlter so that the ﬁlter may be changed without removing refrigerant from the chiller. Use the following procedure.

1. Make sure the compressor is off and that the compressor

disconnect is open.

2. Disconnect the power to the oil heater and oil pump.

3. Close the valves to the ﬁlter.

4. Relieve the pressure from within the ﬁlter by using the

pressure connection on the oil feed line valve to the compressor. Run a hose from the connection to a bucket to catch the oil.

*Water out line is hidden behind oil out line.

Fig. 44 — Typical Compressor or Gear Oil Cooler/Filter

Page 77

5. Open the drain located on the shell of the cooler/ﬁlter. Run a hose from the drain to a bucket to catch the oil.

6. Once the pressure has been relieved and the oil drained, loosen the bolts that hold the cover on the ﬁlter body. Remove the old ﬁlter cartridges and replace with a new ﬁlter cartridge.Assemble the ﬁlter assembly (ﬁlters, spacer, and stopper assembly), and make sure that the spring is centered against the ﬁlter assembly as shown in Fig. 44.

7. Replace the drain ﬁtting, using standard practices to ensure a leak-tight joint. Evacuate the air from the cooler/ ﬁlter assembly.

8. Once the assembly has been evacuated, open the isolation valves.

9. Connect power to the oil heater and oil pump. The oil heater should turn on and warm the oil to 140 to 150 F (60 to 66 C). Operate the oil pump for 2 minutes.Add oil, if required, to keep the level up in the lower sight glass.

Oil should be visible in the reservoir sight glass during all

operating and shutdown conditions. EXTERNAL GEAR OIL FILTER — Change the oil ﬁlter

annually or whenever the chiller is open for repairs. The 17EX external gear lubrication system has an isolatable ﬁlter. Use the following procedure.

1. Make sure that the compressor is off and the compressor disconnect is open.

2. Disconnect the power to the oil heater, if equipped, and to the oil pump.

3. Close the line valves to the ﬁlter.

4. Relieve any pressure from within the ﬁlter by using the pressure connection on the oil feed line valve to the compressor. Run a hose from the connection to a bucket to catch the oil.

5. Open the drain located on the shell of the cooler/ﬁlter. Run a hose from the connection to a bucket to catch the oil.

6. Once the pressure has been removed and the oil drained, loosen the bolts that hold the cover on the ﬁlter body. Remove the oil ﬁlter cartridges and replace with new cartridges. Assemble the ﬁlter assembly (ﬁlters, spacer, and stopper assembly), and make sure that the spring is centered against the ﬁlter assembly, as shown in Fig. 44.

7. Replace the drain ﬁtting, using standard practices to ensure a leak-tight joint.

8. Open the isolation valves.

9. Connect power to the oil heater,if equipped, and oil pump. Operate the oil pump for 2 minutes. Add oil, if required, to keep the level up in the sight glass.

Oil should be visible in the reservoir sight glass during all

operating and shutdown conditions.

Oil Speciﬁcations — If oil is to be added, it must meet

the Carrier speciﬁcations shown in Table 11.

Oil Changes — Carrier recommends changing the oil

after the ﬁrst year of operation and every three to ﬁve years thereafter as a minimum. Carrier also recommends a yearly oil analysis. However, if a continuous oil monitoring system is functioning and a yearly oil analysis is performed, the time between oil changes can be extended.

COMPRESSOR OIL

1. Open the control and oil heater circuit breaker.

2. Drain the oil reservoir by opening the oil charging valve, (Fig. 2, Item 22). Slowly open the valve against refrigerant pressure.

3. Change the oil ﬁlter at this time. See the Changing the Oil Filters section, page 76.

4. Charge the chiller with approximately 20 gallons (76 L) of oil for FX (size 531-599) style compressors in order to bring the level to the middle of the upper sight glass (Fig. 2, Item 21). Turn on the power to the oil heater and let the PIC warm it up to at least 140 F (60 C). Operate the oil pump manually, through the control test, for 2 minutes. The oil level should be between the lower sight glass and one-half full in the upper sight glass for shutdown conditions.

EXTERNAL GEAR OIL — Proper lubrication is vital to maintain gear drive performance.After 500 hours or 4 weeks of initial operation, whichever is ﬁrst, the external gear drive should be thoroughly drained, ﬂushed, and reﬁlled with the proper lubricant. Under normal operating conditions, the lubricant should be changed every 2500 hours or 6 months, whichever comes ﬁrst. This change frequency can be extended if an oil sample analysis indicates a very limited degradation or contamination.

Table 11 — 17EX Chiller Oil Speciﬁcations

SPECIFICATION COMPRESSOR

Oil Type* Inhitited Polyolester-Based

Viscosity at 100 F (37 C)

Carrier Part Number PP23BZ107 PP23BZ091 PP23BB005 PP23BZ103 Carrier Speciﬁcation PP47-12 PP16-0 PP16-2 PP47-31 Recommended

Manufacturer

Capacity 20 gal (76 L) 0.6 gal (2.3 L) per bearing 17 gal (41.6L) Compressor:

LEGEND SSU — Saybolt Universal Seconds *Oil type speciﬁed for chillers using HFC-134a refrigerant.

Synthetic Compressor Oil ISO 68

(300 SSU)

ICI, Emkarate RL68H Mobil, DTE Light

MOTOR SLEEVE

BEARINGS

Mineral-Based, Rust and Oxidation Inhibited Turbine Grade Oil

ISO 32 (150 SSU)

Texaco, Regal R & 0432 Sun Oil, Sunvis 932 Chevron, GST ISO 32

Rust and Oxidation Inhibited Oil

ISO 68 (300 SSU)

Mobil Oil, DTE Heavy Medium Texaco, Regal UR & 068 Chevron, OC #68 NOCO, Turbine T-68

EXTERNAL

GEAR

PUMPOUT

COMPRESSOR

AND OIL

SEPARATOR

Reciprocating Compressor Oil

ISO 68 (300 SSU)

Castrol Icematic SW68 ICI Emkarate RL68HP

4.5 pints (2.6 L)

Oil Separator:

1 pint (0.6 L)

Page 78

The lubricant should be drained while the gear is at operating temperature. The gear drive should be cleaned with a ﬂushing oil. Used lubricant and ﬂushing oil should be completely removed from the system to avoid contaminating new oil.

To change the oil in the external gear:

1. Make sure that the compressor is off and the disconnect

for the compressor is open.

2. Disconnect the power to the oil heater, if equipped, and

the oil pump.

3. Open the drain located on the shell of the cooler/ﬁlter.

Run a hose from the drain to a bucket to catch the oil.

4. Once the pressure has been removed and the oil drained,

loosen the bolts that hold the cover on the ﬁlter body. Remove the old ﬁlter cartridges. Assemble the ﬁlter assembly (ﬁlters, spacer, and stopper assembly), and make sure that the spring is centered against the ﬁlter assembly as shown in Fig. 44.

5. Replace the drain ﬁtting, using standard practices to en-

sure a leak-tight joint.

6. Open the isolation valves and add new oil. Refer to

Table 11 for oil speciﬁcations.

7. Connect power to the oil heater, if equipped, and the oil

pump. Operate the oil pump for 2 minutes. Add oil, if required, to keep the level up in the sight glass.

MOTOR SLEEVE BEARING AND PUMPOUT COMPRESSOR OIL — For instructions on changing the motor sleeve bearing oil, refer to the section on Motor Maintenance, this page.

For instructions on changing the optional pumpout compressor and oil separator oil, refer to the section on Pumpout System Maintenance, page 83.

Inspect Refrigerant Float System — Inspect the

refrigerant ﬂoat system once every 5 years or when the economizer/storage vessel is opened for service. Transfer the refrigerant into the cooler vessel or into a storage tank. There are two ﬂoats on the 17EX, one on each side of theeconomizer/ storage vessel. Remove the ﬂoat access covers. Clean the chambers and valve assembly thoroughly. Be sure that the valves move freely. Make sure that all openings are free of obstructions. Examine the cover gaskets and replace if necessary. See Fig. 45 for a view of both ﬂoats.

InspectRelief ValvesandPiping — The relief valves

on this chiller protect the system against the potentially dangerous effects of overpressure. To ensure against damage to the equipment and possible injury to personnel, these devices must be kept in peak operating condition.

As a minimum, the following maintenance is required.

1. At least once a year, disconnect the vent piping at the valve outlet and carefully inspect the valve body and mechanism for any evidence of internal corrosion or rust, dirt, scale, leakage, etc.

2. If corrosion or foreign material is found, do not attempt to repair or recondition. Replace the valve.

3. If the chiller is installed in a corrosive atmosphere or the relief valves are vented into a corrosive atmosphere, make valve inspections at more frequent intervals.

Coupling Maintenance — Proper coupling mainte-

nance is important since the coupling supports the outboard end of the compressor high speed shaft. Clean and inspect both couplings for wear yearly. Misalignment causes undue noise and wear. Check alignment yearly, or more often if vibration or heating occur. Refer to Chiller Alignment section, page 71.

Never operate the drive without the coupling guards in place. Contact with a rotating shaft or coupling can cause serious injury.

Motor Maintenance — A carefully planned and ex-

ecuted program of inspection and maintenance will do much to ensure maximum motor availability and minimum maintenance cost. If it becomes necessary to repair, recondition, or rebuild the motor, it is recommended that the nearest Westinghouse repair facility be consulted.

In addition to a daily observation of the appearance and operation of the motor, it is recommended that a general inspection procedure be established to periodically check the following items:

• cleanliness, both external and internal

• stator and rotor (squirrel-cage) windings

• bearings

Fig. 45 — Typical Float Valve Arrangement

Page 79

CLEANLINESS — On open ventilated motors, screens and louvers over the inlet air openings should not be allowed to accumulate any build-up of dirt, lint, etc., that could restrict free air movement. Screens and louvers should never be cleaned or disturbed while the motor is in operation because any dislodged dirt or debris can be drawn directly into the motor.

If the motor is equipped with air ﬁlters, they should be replaced (disposable type) or cleaned and reconditioned (permanent type) at a frequency that is dictated by conditions. It is better to replace or recondition ﬁlters too often than not often enough.

Washing motors using a water spray is not recommended. Manual or compressed air cleaning is preferred. If it becomes necessary to spray-wash a motor, it should be done with extreme care. Do not aim high pressure sprays directly at air inlet openings, conduit connections, shaft seals, or gasketed surfaces to prevent the possibility of forcing water inside the chiller.

The stator windings of motors with open ventilation systems can become contaminated with dirt and other substances brought into the motor by the ventilating air. Such contaminants can impair cooling of the winding by clogging the air passages in the winding end-turns and vent ducts through the stator core and by reducing heat transfer from the winding insulation surfaces to the cooling air. Conducting contaminants can change or increase electrical stresses on the insulation, and corrosive contaminants can chemically attack and degrade the insulation. This may lead to shortened insulation life and stator failure.

Several satisfactory methods of cleaning stator windings and stator cores are offered below:

Compressed Air — Low pressure (30 psi maximum), clean (no oil) dry air can be used to dislodge loose dust and particles in inaccessible areas such as air vent ducts in the stator core and vent passages in the winding end-turns. Excessive air pressure can damage insulation and drive contaminants into inaccessible cracks and crevices.

Vacuum — Vacuum cleaning can be used, both before and after other methods of cleaning, to remove loose dirt and debris. It is a very effective way to remove loose surface contamination from the winding without scattering it. Vacuum cleaning tools should be nonmetallic to avoid any damage to the winding insulation.

Wiping — Surface contamination on the winding can be removed by wiping, using a soft, lint-free wiping material. If the contamination is oily, the wiping material can be moistened (not dripping wet) with a safety-type petroleum solvent, such as Stoddard solvent. In hazardous locations, a solvent such as inhibited methyl chloroform may be used, but must be used sparingly and immediately removed. While this solvent is non-ﬂammable under ordinary conditions, it is toxic. Proper health and safety precautions should be followed while using it.

Solvents of any type should never be used on windings provided with abrasion protection. Abrasion protection is a grey, rubber-like coating applied to the winding end-turns.

Adequate ventilation must always be provided in any area where solvents are being used to avoid the danger of ﬁre, explosion, or health hazards. In conﬁned areas (such as pits) each operator should be provided with an air line respirator, a hose mask, or a self-contained breathing apparatus. Operators should wear goggles, aprons, and suitable gloves. Solvents and their vapors should never be exposed to open ﬂames or sparks and should always be stored in approved safety containers.

SLEEVE BEARINGS Oil Changing — The oil reservoirs of the self lubricated bear-

ings should be drained and reﬁlled every 6 months. More frequent changes may be needed if severe oil discoloration or contamination occurs. In conditions where contamination does occur, it may be advisable to ﬂush the reservoir with kerosene to remove any sediment before new oil is added. Proper care must be taken to thoroughly drain the reservoir of the ﬂushing material before reﬁlling it with the new oil.

Reﬁll the reservoir to the center of the oil sight glass with a rust and oxidation inhibited, turbine grade oil. The viscosity of the oil must be 32 ISO (150 SSU) at 100 F (37.7 C). Oil capacity in each of the 2 bearings is 0.6 gal. (2 l) per bearing. Use of Carrier Oil Speciﬁcation PP16-0 is approved (refer to Table 11).

Disassembly — The bearing sleeve is spherically seated and self-aligning. The opposite drive end bearing is normally insulated for larger motors (or when speciﬁed). On some motors, the insulation is bonded to the spherical seat of the bearing housing. Use extreme care when removing the sleeve from the insulated support to avoid damaging this insulation.

Note that some bolts and tapped holes associated with the bearing housings, bearing sleeves, and seals are metric.

The following procedure is recommended for removing the bearing sleeve.

1. Remove the oil drain plug in the housing bottom and drain the oil sump.

2. Remove all instrumentation sensors that are in contact with the bearing sleeve. These include resistance temperature detectors, thermocouples, temperature relay bulbs, thermometers, etc.

3. Remove the end cover.

4. Remove the socket head bolts holding the bearing cap and the inner air seal together at the horizontal split. The front end cover plate must also be removed if the front bearing is being disassembled. Remove the bearing cap and top half of the inner air seal by lifting straight up to avoid damaging the labyrinth seals. Place themon a clean, dry surface to avoid damage to the parting surfaces.

5. Remove any split bolts that may be holding the two bearing halves together. Remove the top half of the bearing sleeve using suitable eyebolts in the tapped holes provided. Lift the bearing top straight up and avoid any contact with the shoulders of the shaft journals that might damage the thrust faces of the bearing. Place on a clean, dry surface, taking care to prevent damage to either the parting surfaces or the locating pins that are captive in the top bearing half.

6. Remove the 4 screws at the partings in the oil ring and dismantle the ring by gently tapping the dowel pin ends with a soft-faced mallet. Remove the ring halves and immediately reassemble them to avoid any mixup in parts or damage to the surfaces at the partings.

Page 80

7. When removing the labyrinth seals, note the position of the anti-rotation button located on the inside of the top half of the seal. Pull up the garter spring surrounding the ﬂoating labyrinth seal and carefully slip out the top half. Rotate the garter spring until the lock is visible. Twist counterclockwise to disengage the lock, remove the garter spring, then rotate the lower half of the seal out of the groove in the bearing housing while noting the orientation of the oil drain holes. Note the condition of these ﬂoating labyrinth seals. If they are cracked or chipped, they must be replaced. Do not attempt to reuse a damaged seal.

8. To remove the bottom bearing half, the shaft must be raised a slight amount to relieve pressure on the bearing. On the rear end, this can be done by jacking or lifting on the shaft extension. (Care must be taken to protect the shaft from damage.) On the front end, jacking or lifting can be done using bolts threaded into the tapped holes provided in the shaft end.

NOTE: Lift only enough to free the bearing; overlifting the shaft can cause difficulty in removing the bearing.

9. Roll the bottom bearing half to the top of the shaft journal and then lift it using suitable eyebolts threaded into the holes provided. Again, avoid any contact with the shaft shoulders that could damage the bearing thrust faces. Place the lower bearing half on a clean, dry surface to protect the parting surfaces.

Use extreme care when rolling out the lower bearing half. Keep the hands and ﬁngers well clear of any position where they might be caught by the bearing half if it were accidentally released and rotated back to its bottom position. Serious personal injury could result.

10. Protect the shaft journal by wrapping it with clean, heavy paper or cardboard.

Reassembly — Bearing reassembly is basically a reversal of the disassembly procedures outlined above, with the following additional steps.

Curil-T is the only approved compound for use in the assembly of the bearings on this motor. Other products may harden and impede the operation.

During the reassembly of the bearing parts, a thin layer of Curil-T should be applied to all gasketed and machined interface surfaces. This suggestion does not apply to the machined surfaces of the bearing liner halves.

1. The interior of the bearing housing should be cleaned and then ﬂushed with clean oil or kerosene.

2. The bearing halves and the shaft journal should be wiped clean using lint-free cloth soaked with clean oil.

3. All parts should be carefully inspected for nicks, scratches, etc., in any contact surfaces. Such imperfections should be removed by an appropriate method such as stoning, scraping, ﬁling, etc., followed by thorough cleaning.

4. Apply afew drops of oil to the journal and bearing saddles.

5. Roll the bottom half of the bearing into place and lower the shaft.

6. Before installing the ﬂoating labyrinth seal halves, observe their condition. Do not attempt to use a cracked or chipped seal. The bottom half seal has a set of drilled holes in its side face. These must be placed at the bottom toward the inside of the bearing so that accumulating oil may drain back into the housing.

7. Put a small bead of Curil-T around the bottom seal half outside diameters on both sides adjacent to the garter spring groove. This prevents oil from bypassing the seal around its outside.

8. Place the bottom seal half on top of the shaft (ensuring that the proper orientation of the drain holes is provided) and roll it into position. Install the top half of the seal making sure that the anti-rotation button is located in the proper position on the inboard side of the bearing. Insert the garter spring pulling up on both ends to permit engaging the lock. Run a small bead of Curil-Taround the outside diameters on both sides adjacent to the garter spring groove on this half also.

9. Carefully reassemble the two oil ring halves. Inspect the dowel pins for burrs and straightness and make any corrections required. Do not force the ring halves together. Excessive force may alter the roundness or ﬂatness of the ring which can change its oil delivery performance. Apply locking compound to the oil ring screws prior to reassembly.

10. Assemble the top half of the bearing liner making sure that the match marks on the liner halves align with one another.Failure to ensure alignment of match marks can cause misalignment and possible damage to bearings and journal surfaces. Reinstall any split bolts, if supplied, between the bearing halves.

11. Some of the pipe plugs in the housing are metric thread type and have a copper, lead, or similar material washer. If these plugs are removed, be careful not to lose the washers. Before reassembly, inspect the washers and replace them if required.

12. Before installing the bearing cap, observe the position of the ﬂoating labyrinth seal. The ‘‘tab’’ must be on top to engage the pocket. Failure to position the seal properly will result in damage when the cap is assembled.

13. Carefully lower the bearing housing cap over the ﬂoating seals. Keep the bearing cap level to avoid binding and possibly damaging the seals. The bearing cap should seat evenly on the bearing housing base.

When seating the bearing shell, apply a thin layer of lubricating oil at the spherical surface of the liner. Slowly roll the lower bearing liner into the bearing housing making sure that the split surfaces of the liner and the housing are ﬂush. Gradually lower the shaft onto the bearing. The weight of the shaft will help rotate the bearing liner so that the babbitt surface of the liner will match the slope of the journal. Sometimes it is necessary to use a rubber mallet to tap lightly on the bearing housing while slowly rolling the shaft to help this seating operation.

Do not force the bearing cap down. Damage could occur to the labyrinth seals.

If the bearing cap does not seat completely, remove and reset the ﬂoating labyrinth seal position. When installing upper bearing cap, the ﬂoating labyrinth seals sometimes rotate and the anti-rotation ‘‘tab’’ does not seat in its holder, thus preventing the bearing housing from seating properly. This procedure should be repeated until the bearing cap seats properly.

Page 81

14. Reinstall the bearing housing split bolts. Before torquing bearing housing cap bolts, rotate the shaft by hand while bumping the bearing housing with a rubber or rawhide mallet in the horizontal and axial planes to allow the bearings to align themselves to the shaft journals.

15. Torque the bearing housing cap bolts by following the torque values as provided in Table 6 on page 51.

Motor Handling/Rigging — Each motor is provided

with lifting lugs, welded to the four corners of the motor frame, for lifting the assembled chiller. The motor should always be lifted by using the lifting lugs located on all four corners of the motor frame. (See Fig. 46.)

Spreader bars of adequate capacity and number must be used to avoid applying any pressure against the top air housing with the lifting plugs.

provide proper protection while the motor is being stored. The motor should be stored under cover in a clean, dry location and should be protected from rapid temperature changes.

Since moisture can be very detrimental to electrical components, the motor temperature should be maintained at approximately 5° F (3° C) above the dew point temperature by providing either external or internal heat. If the motor is equipped with space heaters, they should be energized at the voltage shown by the space heater nameplate attached to the motor.Incandescent light bulbs can be placed within the motor to provide heat. However, if used, they must not be allowed to come in contact with any parts of the motor because of the concentrated hot spot that could result.

This motor has been provided with a shaft shipping brace or shipping bolt (normally painted yellow) to prevent shaft movement during transit, it must be removed to allow shaft rotation (refer to Before Initial Start-Up, Remove Shipping Packaging section, page 45). It is very important that this brace be reinstalled exactly as it was originally, before the motor is moved from storage or any time when the motor is being transported. This prevents axial rotor movement that might damage the bearings.

Motors equipped with sleeve bearings are shipped from the factory with the bearing oil reservoirs drained. In storage, the oil reservoirs should be properly ﬁlled to the center of the oil level gage with a good grade of rust inhibiting oil (refer to the certiﬁed drawing for oil viscosity and any special requirements). To keep the bearing journals well oiled and to prevent rusting, the motor shaft should be rotated several revolutions every 2 weeks. While the shaft is rotating it should be pushed to both extremes of the endplay to allow for oil ﬂow over the entire length of the journals.

Fig. 46 — Motor Riggings

If the motor is lifted with the top air housing removed, the angle of the lifting slings with the horizontal should never be less than 45 degrees.

Withthe exclusion of the TEWACcooler, the top air housing is provided with

⁄4-10 tapped holes for lifting devices to be installed in order to remove the air housing from the motor. The top air housing can be detached by removing the enclosure holddown bolts, located in the inside corners of the enclosure. These enclosure holddown bolts are accessed through the louver/screens located on the front and rear end of the chiller or through access panels bolted to the sides of the enclosure.

Uneven lifting must always be avoided. When single point lifting is to be used, slings of equal lengths must always be used to avoid uneven lifting.

Under no circumstances should the motor be lifted using the shaft as an attachment point.

NOTE: Refer to weights speciﬁed on certiﬁed drawing to determine proper lifting equipment required for speciﬁc components or assemblies.

Motor Storage — If the chiller is to be placed in ex-

tended shutdown, certain precautions must be taken to

External Gear Storage — All internal and unpainted

external surfaces of the gear drives have been treated with a rust preventative at the factory before shipment. The protective life of the rust preventative varies with temperature ﬂuctuations, atmospheric moisture content, degree of exposure to the elements during storage, and degree of contact with other objects.

Inspect all machined surfaces, and spray or add rust inhibitor to exposed metal surfaces that may have had the protective coating removed during shipping and handling.

T obe sure that the gear drive operates satisfactorily at startup, take certain precautions when you receive it. The expected length of storage and the storage atmosphere dictate the maintenance schedule to be followed. The gear must always be stored in its operating position, level on its mounting feet, and free of loads or weights on input and output shafts.

SHORT-TERM STORAGE (Indoors) — If the units are to be stored for 30 days or less, observe the following precautions.

• Store the unit in a clean, dry location with the factory pack-

ing intact and with as nearly a constant temperature as possible.

• Elevate the unit a minimum of 6 in. above the ﬂoor level.

• Avoid areas that are subject to extremes in temperature,

vibration, and humidity.

LONG-TERM STORAGE (Indoors) — If the unit is to be stored for more than 30 days, observe the following precautions. Store in a clean, dry location. Elevate the unit at a minimum of 6 in. above the ground ﬂoor level. Avoid areas that are subject to extremes in temperature, vibration, and humidity. In addition, do one of the following:

• Remove the breather and replace it with pipe plugs. Pack

the entire seal area with grease to form a vapor barrier and seal with tape.

Page 82

Fill the gear drive to the recommended oil level with heated Shell VSI grade 68 oil or its equivalent, heated between 110 and 120 F (43 and 49 C). Do not overﬁll. Immediately close the openings to keep the vapors in the housing.

Inspect the unit every 30 days and spray or add rust inhibitor suitable for anticipated storage conditions, as required.

Drain and replace the oil with the recommended oil type prior to start-up.

• Remove the breather and replace it with a pipe plug. Pack the entire seal area with grease to form a vapor barrier and seal it with tape. A vapor-phase rust inhibitor, such as Daubert Chemical, Non-Rust Motorstor VCi-10 or its equivalent, may be added to the recommended oil type in the amount of 2% of the total sump capacity. Fill the unit to the recommended level. Do not overﬁll.

Inspect the unit every 30 days and spray or add rust inhibitor suitable for anticipated storage conditions, as required.

The unit may run without changing this oil mixture.

EXTENDED DOWNTIME — Consider the length of downtime the unit will undergo. The lubricating oil used in the unit should protect the interior parts for up to 30 days of shutdown. If the unit will be shut down longer than 30 days, it must be operated a minimum of 30 minutes every 30 days to distribute the lubricant to all interior parts.

If it is impractical to operate the unit every 30 days, the long-term storage instructions described above must be followed. All seals applied for this storage condition must be removed before operating the unit.

Compressor Bearing Maintenance — The key to

good bearing maintenance is proper lubrication. Use the proper grade of oil, maintained at recommended level, temperature, and pressure. Inspect the lubrication system regularly and thoroughly.

Only a trained service technician should remove and examine the bearings. The bearings should be examined on a scheduled basis for signs of wear. The frequency of examination is determined by the hours of chiller operation, load conditions during operation, and the condition of the oil and the lubrication system. Excessive bearing wear can sometimes be detected through increased vibration or increased bearing temperature. If either symptom appears, contact an experienced and responsible service organization for assistance.

External Gear Maintenance — Perform the re-

quired maintenance and recommended intervals. Good preventive maintenance prolongs the life of the unit.

Daily

• Inspect for leaks and loose connections.

• Check the oil level.

• Check the oil temperature and pressure.

• Check for unusual noise and/or vibration. Weekly — Check the oil ﬁlter.

Monthly

• Obtain oil sample analysis.

• Clean or replace oil ﬁlters.

• Check the foundation mounting bolts for tightness.

• Clean the air ﬁlter.

• Check the operation of all auxiliary equipment. Semi-Annually

• Check gear tooth wear.

• Check the oil and replace it if necessary.

• Check the coupling alignment.

Annually

• Check the heat exchanger for corrosion and clogged tubes.

• Check the bearing clearance and end play. Disassembly andAssembly Instructions — The following in-

structions apply to standard high speed gear units.

• Required Equipment: In addition to standard mechanic’s tools, have the following equipment on hand: hoist, sling, torque wrench, feeler gages, and dial indicator.

• General Instructions: Clean external surfaces of the gear unit before removing the cover to prevent contaminants from falling into it. Record the mounting dimensions and the location of accessories for reference when reassembling. To remove the gear from its operating area, disconnect all connected equipment and lift the gear from its foundation using 4 lifting lugs.

Inspect the Heat Exchanger Tubes

COOLER — Inspect and clean the cooler tubes at the end of the ﬁrst operating season. Because these tubes have internal ridges, a rotary-type tube cleaning system is necessary to fully clean the tubes. Upon inspection, the tube condition determines the scheduled frequency for cleaning and indicates whether water treatment is adequate in the chilled water/ brine circuit. Inspect the entering and leaving chilled water temperature sensors for signs of slime, corrosion, or scale. Replace the sensor if corroded or remove any scale if found.

CONDENSER — Since this water circuit is usually an opentype system, the tubes may be subject to contamination and scale. Clean the condenser tubes with a rotary tube cleaning system at least once per year and more often if the water is contaminated. Inspect the entering and leaving condenser water sensors for signs of slime, corrosion, or scale. Replace the sensor if corroded or remove any scale if found.

Higher than normal condenser pressures, together with the inability to reach full refrigeration load, usually indicate dirty tubes or air in the chiller. If the refrigeration log indicates a rise above normal condenser pressures, check the condenser refrigerant temperature against the leaving condenser water temperature. If this reading is more than what the design difference is supposed to be, then the condenser tubes may be dirty, or water ﬂow may be incorrect. Because HFC 134a is a high-pressure refrigerant, air usually does not enter the chiller; rather, the refrigerant leaks out.

During the tube cleaning process, use brushes especially designed to avoid scraping and scratching the tube wall. Contact your Carrier representative to obtain these brushes. Do

not use wire brushes.

Hard scale may require chemical treatment for its prevention or removal. Consult a water treatment specialist for proper treatment.

WaterLeaks— Waterin the refrigerant is indicated dur-

ing chiller operation by the refrigerant moisture indicator on the refrigerant motor cooling line. Water leaks should be repaired immediately.

The chiller must be dehydrated after repair of water leaks. See Chiller Dehydration section, page 49.

WaterTreatment— Untreated or improperly treated wa-

ter may result in corrosion, scaling, erosion, or algae. The services of a qualiﬁed water treatment specialist should be obtained to develop and monitor a treatment program.

Page 83

Water must be within design ﬂow limits, clean, and treated to ensure proper chiller performance and reduce the potential of tube damage due to corrosion, scaling, erosion, and algae. Carrier assumes no responsibility for chiller damage resulting from untreated or improperly treated water.

Inspect the Starting Equipment — Before work-

ing on any starter, shut off the chiller, and open all disconnects supplying power to the starter.

The disconnect on the starter front panel does not deenergize all internal circuits. Open all internal and remote disconnects before servicing the starter.

Never open isolating knife switches while equipment is operating. Electrical arcing can cause serious injury.

Inspect the starter contact surfaces for wear or pitting on mechanical-type starters. Do not sandpaper or ﬁle silverplated contacts. Follow the starter manufacturer’s instructions for contact replacement, lubrication, spare parts ordering, and other maintenance requirements.

Periodically vacuum or blow off accumulated debris on the internal parts with a high-velocity, low-pressure blower.

Power connections on newly installed starters may relax and loosen after a month of operation. Turn power off and retighten. Recheck annually thereafter.

Loose power connections can cause voltage spikes, overheating, malfunctioning, or failures.

Check Pressure Transducers — Prior to start-up

and once a year, the pressure transducers should be checked against a pressure gage reading. Check all three transducers: oil pressure, condenser pressure, and cooler pressure.

Note the evaporator and condenser pressure readings on the STATUS01 screen on the LID. Attach an accurate set of refrigeration gages to the cooler and condenser Schrader ﬁttings. Compare the two readings. If there is a difference in readings, the transducer can be calibrated, as described in the Troubleshooting Guide section.

Pumpout System Maintenance — For compres-

sor maintenance details, refer to the 06D, 07D Installation, Start-Up, and Service Instructions.

OPTIONALPUMPOUTCOMPRESSOR OIL CHARGE — Use oil conforming to Carrier speciﬁcations for reciprocating compressor usage. See Table 11.

Oil should be visible in the compressor sight glass both during operation and at shutdown. Always check the oil level before operating the compressor.Before adding or changing oil, relieve the refrigerant pressure as follows:

1. Attach a pressure gage to the gage port of either com-

pressor service valve (Fig. 34).

2. Close the suction service valve and open the discharge

line to the storage tank or the chiller.

3. Operate the compressor until the crankcase pressure drops

to 2 psig (13 kPa).

4. Stop the compressor and isolate the system by closing the discharge service valve.

5. Slowly remove the oil return line connection. Add oil as required.

6. Replace the connection and reopen the compressor service valves.

PUMPOUT SAFETY CONTROL SETTINGS (Fig. 47) — The pumpout system high-pressure switch should open at 161 psig (1110 kPa) and close at 130 psig (896 kPa). Check the switch setting by operating the pumpout compressor and slowly throttling the pumpout condenser water.

Fig. 47 — Controls for Optional Pumpout

Compressor

Ordering Replacement Chiller Parts — When or-

dering Carrier speciﬁed parts, the following information must accompany an order:

• chiller model number and serial number

• name, quantity, and part number of the part required

• delivery address and method of shipment

MOTOR REPLACEMENT PARTS — Replacement or renewal parts information for the motor and any auxiliary devices can be obtained from the nearest Westinghouse Motor Company sales office. A complete description of the needed part(s) is necessary, together with the complete motor nameplate reading for positive motor identiﬁcation.

EXTERNAL GEAR REPLACEMENT PARTS — Replacement or renewal parts information for the external gear and any auxiliary devices can be obtained from the nearest Nuttall or Lufkin sales office.Acomplete description of theneeded part(s) is necessary, together with the complete gear nameplate reading for positive identiﬁcation.

TROUBLESHOOTING GUIDE

Overview —

erator and the technician troubleshoot a 17EX chiller.

• By using the LID display, the actual operating conditions

of the chiller can be viewed while the unit is running.

• The CONTROL ALGORITHM STATUS table includes

screens with information that can be used to diagnose problems with chilled water temperature control, chilled water

The PIC has many features to help the op-

Page 84

temperature control overrides, hot gas bypass, surge algorithm status, and time schedule operation. Refer to Fig. 14 and Table 2, Examples 11-14.

• The control test feature checks for proper operation and tests the temperature sensors, pressure transducers, theguide vane actuator, oil pumps, water pumps, tower control, and other on/off outputs while the compressor is stopped. It also has the ability to lock off the compressor and turn on water pumps for pumpout operation. The LID display shows the required temperatures and pressures during these operations. Refer to Fig. 16 for the CONTROL TEST menu structure and to the Control Testsection, page 85, for more information on this feature.

• Other SERVICE menu tables can access conﬁgured items, such as chilled water resets, override set points, etc.

• If an operating fault is detected, an alarm message is generated and displayed on the LID default screen. A more detailed message, along with a diagnostic message, is also stored in the ALARM HISTORY table in the PIC.

Checking the Display Messages — The ﬁrst area

to check when troubleshooting the 17EX is the LID display. If the alarm light is ﬂashing, check the primary and secondary message lines on the LID default screen (Fig. 11). These messages indicate where the fault is occurring. The ALARM HISTORY table on the SERVICE menu also carries an alarm message to further expand on this alarm. For a complete list of alarm messages, see Table 12. If the alarm light starts to

ﬂash while accessing a menu screen, depress the EXIT key to return to the default LID screen to read the failure

message. The compressor does not run while an alarm condition exists unless the alarm type is an unauthorized start or a failure to shut down.

soft-

Checking Temperature Sensors — All tempera-

ture sensors are thermistors. This means that the resistance of the sensor varies with temperature. All sensors have the same resistance characteristics. Determine sensor temperature by measuring voltage drop if the controls are powered, or resistance if the controls are powered off. Compare the readings to the values listed in Table 14A or 14B.

RESISTANCE CHECK — Turn off the control power and disconnect the terminal plug of the sensor in question from the module. Witha digital ohmmeter,measure the sensor resistance between the receptacles designated by the wiring diagram. The resistance and corresponding temperature are listed in Table14A or 14B. Check the resistance of both wires to ground. This resistance should be inﬁnite.

VOLTAGE DROP — Using a digital voltmeter, the voltage drop across any energized sensor can be measured while the control is energized. Table 14A or 14B lists the relationship between temperature and sensor voltage drop (volts dc measured across the energized sensor). Exercise care when measuring voltage to prevent damage to the sensor leads, connector plugs, and modules. The sensor wire should also be checked at the sensor plug connection. Check the sensor wire by removing the condenser at the sensor and measure for 5 vdc back to the module, if the control is powered.

Relieve all refrigerant pressure or drain the water prior to replacing the temperature sensors.

CHECK SENSOR ACCURACY — Place the sensor in a medium of a known temperature and compare that temperature to the measured reading. The thermometer used to determine the temperature of the medium should be of laboratory quality with 0.5° F (.25° C) graduations. The sensor in question should be accurate to within 2° F (1.2° C).

See Fig. 6 for sensor locations. The sensors are immersed directly in the refrigerant or water circuits. The wiring at each sensor is easily disconnected by unlatching the connector. These connectors allow only one-way connection to the sensor. When installing a new sensor, apply a pipe sealant or thread sealant to the sensor threads.

DUAL TEMPERATURE SENSORS — There are 2 sensing elements on each of the bearing temperature sensors for servicing convenience. In case one of the dual sensors is damaged, the other one can be used by moving a wire.

The number 1 terminal in the sensor terminal box is the common line. To use the second sensor, move the wire from the number 2 position to the number 3 position.

CheckingPressureTransducers— The 17EX chiller

has 5 transducers. These transducers sense cooler pressure, condenser pressure, compressor oil supply pressure, oil sump, and gear oil supply pressure. The compressor oil supply pressure and the oil transmission sump pressure differenceis calculated by a differential pressure power supply module. The PSIO then reads this differential. In effect, then, the PSIO reads 3 pressure inputs. The cooler and condenser transducers are used by the PIC to determine refrigerant temperatures.

All pressure inputs can be calibrated, if necessary.It is not usually necessary to calibrate at initial start-up. However, at high altitude locations, calibration of the transducer will be necessary to ensure the proper refrigerant temperature/ pressure relationship. Each transducer is supplied with 5 vdc power from a power supply .If the power supply fails, a transducer voltage reference alarm occurs. If the transducer reading is suspected of being faulty, check the supply voltage. It should be 5 vdc ± .5 v. If the supply voltage is correct, the transducer should be re-calibrated or replaced.

To calibrate oil pressure differential, refer to Oil Pressure Differential Calibration at the end of this section.

Calibration can be checked by comparing the pressure readings from the transducer against an accurate refrigeration gage. These readings are all viewed or calibrated from the STATUS01 screen on the LID. The transducer can be checked and calibrated at 2 pressure points. These calibration points are 0 psig (0 kPa) and between 240 and 260 psig (1655 to 1793 kPa). To calibrate these transducers:

1. Shut down the compressor.

2. Disconnect the transducer in question from its Schrader

ﬁtting. NOTE: If the cooler or condenser vessels are at 0 psig

(0 kPa) or are open to atmospheric pressure, the transducers can be calibrated for zero without removing the transducer from the vessel.

3. Access the STATUS01 screen, and view theparticular trans-

ducer reading; it should read 0 psi (0 kPa). If the reading is not 0 psi (0 kPa), but within ± 5 psi (35 kPa), the

value may be zeroed by pressing the SELECT while the parameter for the transducer is highlighted. Then, press the ENTER

to zero. If the transducer value is not within the calibration range,

the transducer returns to the original reading. If the LID pressure value is within the allowed range (noted above), check the voltage ratio of the transducer. To obtain the voltage ratio, divide the voltage (dc) input from the transducer by the supply voltage signal, measured at the PSIO terminals J7-J34 and J7-J35. For example, the condenser transducer voltage input is measured at PSIO terminals J7-1 and J7-2. The voltage ratio must be between

0.80 vdc and 0.11 vdc for the software to allow calibration. Pressurize the transducer until the ratio is within range. Then attempt calibration again.

softkey.The value will now go

softkey

Page 85

4. A high pressure point can also be calibrated between 240 and 260 psig (1655 and 1793 kPa) by attaching a regulated 250 psig (1724 kPa) pressure (usually from a nitrogen cylinder). The high pressure point can be calibrated by accessing the appropriate transducer on the

STATUS01 screen, highlighting the transducer, pressing the SELECT

softkey, and then increasing or decreasing

the value to the exact pressure on the refrigerant gage. Press ENTER

to ﬁnish. High altitude locations must compensate the pressure so that the temperature/pressure relationship is correct.

If the transducer reading returns to the previous value and the pressure is within the allowed range, check the voltage ratio of the transducer. Refer to Step 3 above. The voltage ratio for this high pressure calibration must be between 0.585 and 0.634 vdc to allow calibration. Change the pressure at the transducer until the ratio is within the acceptable range. Then attempt to calibrate to the new pressure input.

The PIC will not allow calibration if the transducer is too far out of calibration. A new transducer must be installed and re-calibrated.

OILDIFFERENTIALPRESSURE/POWER SUPPLYMODULE CALIBRATION — (See Fig. 48.) The oil reservoir in the 17EX chiller is not common to cooler pressure. Therefore, a comparison of pump output to cooler pressure can not be used to provide differential oil pressure information. A different method has been developed.

Oil transmission sump pressure and oil supply pressure are fed to a comparator circuit on a 5V power supply board. The output of this circuit, which represents differential oil pressure, is fed to the PSIO. The oil differential pressure is calibrated to 0 psid (0 kPad) by selecting the oil pressure input on the STATUS01 screen. Then, with the oil pump turned

OFF and the transducers connected, press the ENTER key to zero the point. No high end calibration is needed or

possible.

soft-

17EX OIL PRESSURE INPUT

TROUBLESHOOTING TRANSDUCERS — When troubleshooting transducers, keep the negative lead of your voltohmmeter on terminal U4 of the power supply (or terminal 4 on power supplies without the comparator circuit).

Voltage VO1 = (VH1-VL1) + .467 ± .1 V For all PIC transducers: Measured pressure = (507.97 × (V

= transducer output ref. to neg. terminal

out

(4 or U4) i.e., VH1 to U4 or VL1 to U4

out/Vin

)) − 47.33

Vin= power supply output, i.e., U3 to U4

TRANSDUCER REPLACEMENT — Since the transducers are mounted on Schrader-type ﬁttings, there is no need to remove refrigerant from the vessel. Disconnect the transducer wiring by pulling up on the locking tab while pulling up on the weather-tight connecting plug from the end of the transducer. Do not pull on the transducer wires. Unscrew the transducer from the Schrader ﬁtting. When installing a new transducer, do not use pipe sealer, which can plug the sensor. Put the plug connector back on the sensor and snap into place. Check for refrigerant leaks.

Make sure to use a backup wrench on the Schrader ﬁtting whenever removing a transducer.

ControlAlgorithms Checkout Procedure — One

of the tables in the SERVICE menu is the CONTROL ALGORITHM STATUS table. This table has 6 screens that may be viewed to see how a particular control algorithm is operating, that is, to see what parameters and values the PIC is using to control the chiller.

MAINT01 Capacity MAINT02 Override MAINT03 Surge/

MAINT04 LEAD/LAG OCCDEFM Time

WSMDEFME Water

Control Status HGBP

Status Status Schedules

Status

System Manager Status

These maintenance tables are very useful in determining guide vane position, reaction from load changes, control point overrides, hot gas bypass reaction, surge prevention, etc.

Thevalues used tocalculatethe chilled water/brine control point.

Detailsofall chilled water controloverride values

The surge and hot gas bypass control algorithm status as well as the values dealing with this control.

LEAD/LAG operation status. The Local and CCN occupied sched-

ules,displayedin a waythatallows the operator toquickly determine whether the schedule is in an occupied period or not.

The status of the WSM (water system manager),a CCN module thatcan turn on the chiller and change the chilled water control point.

Fig. 48 — Oil Differential Pressure/Power

Supply Module

Control Test — The control test feature can check all

the thermistor temperature sensors, including those on the Options modules, pressure transducers, pumps and their associated ﬂow switches, the guide vane actuator, and other control outputs, such as hot gas bypass. The tests can help to determine whether a switch is defective, or a pump relay is not operating, among other useful troubleshooting tests.

During pumpdown operations, the pumps are energized to prevent freeze-up, and the vessel pressures and temperatures are displayed. The pumpdown/lockout feature prevents the compressor from starting up when there is no refrigerant in the chiller or when the vessels are isolated. The operator then uses the terminate lockout screen to end the pumpdown lockout after the pumpdown procedure is reversed and refrigerant is added.

Page 86

LEGEND FOR TABLE 12, A - N

1CR AUX — Compressor Start Contact CA P

— Compressor Current CCN — Carrier Comfort Network CDFL — Condenser Water Flow CHIL S S

— Chiller Start/Stop CHW — Chilled Water CMPD — Discharge Temperature CRP — Condenser Pressure ERT — Evaporator Refrigerant Temperature EVFL — Chilled Water Flow GV TRG

— Target Guide Vane Position LED — Light-Emitting Diode LID — Local Interface Device

OILPD — Oil Pressure OILT — Oil Sump Temperature PIC — Product Integrated Control PRS TRIP

— Pressure Trip Contact PSIO — Processor Sensor Input/Output Module RLA — Rated Load Amps RUN AUX

— Compressor Run Contact SMM — Starter Management Module SPR PL STR FLT

— Spare Protective Limit Input

— Starter Fault TXV — Thermostatic Expansion Valve VP V REF

—Line Voltage: Percent

— Voltage Reference

MTRB — Bearing Temperature MTRW — Motor Winding Temperature

Table 12 — LID Primary and Secondary Messages and Custom Alarm/Alert Messages

with Troubleshooting Guides

A. SHUTDOWN WITH ON/OFF/RESET-OFF

PRIMARY MESSAGE SECONDARY MESSAGE PROBABLE CAUSE/REMEDY

MANUALLY STOPPED — PRESS CCN OR LOCAL TO START TERMINATE PUMPDOWN MODE TO SELECT CCN OR LOCAL

SHUTDOWN IN PROGRESS COMPRESSOR UNLOADING Chiller unloading before shutdown due to soft/stop feature. SHUTDOWN IN PROGRESS COMPRESSOR DEENERGIZED ICE BUILD OPERATION COMPLETE Chiller shutdown from Ice Build operation.

PIC in OFF mode, press the CCN or local softkey to start unit.

Enter the CONTROL TEST table and select to unlock compressor.

Chillercompressor isbeing commandedto stop.Water pumpsare deenergized within one minute.

TERMINATE LOCKOUT

B. TIMING OUT OR TIMED OUT

PRIMARY MESSAGE SECONDARY MESSAGE PROBABLE CAUSE/REMEDY

READY TO START IN XX MIN UNOCCUPIED MODE READY TO START IN XX MIN REMOTE CONTACTS OPEN Remote contacts have stopped chiller. Close contacts to start. READY TO START IN XX MIN STOP COMMAND IN EFFECT READY TO START IN XX MIN RECYCLE RESTART PENDING Chiller in recycle mode.

READY TO START UNOCCUPIED MODE READY TO START REMOTE CONTACTS OPEN Remote contacts have stopped chiller. Close contacts to start.

READY TO START STOP COMMAND IN EFFECT READY TO START IN XX MIN REMOTE CONTACTS CLOSED Chiller timer counting down unit. Ready for start.

READY TO START IN XX MIN OCCUPIED MODE Chiller timer counting down unit. Ready for start. READY TO START REMOTE CONTACTS CLOSED Chiller timers complete, unit start will commence. READY TO START OCCUPIED MODE Chiller timers complete, unit start will commence. STARTUP INHIBITED LOADSHED IN EFFECT CCN loadshed module commanding chiller to stop.

READY TO START IN XX MIN START COMMAND IN EFFECT

Time schedule for PIC is unoccupied. Chillers will start only when occupied.

Chiller START/STOP on STATUS01 manually forced to stop. Release value to start.

Time schedule for PIC is unoccupied. Chiller will start when occupied. Make sure the time and date have been set on the SERVICE menu.

Chiller START/STOP on STATUS01 manually forced to stop. Release value to start.

Chiller START/STOP on STATUS01 has been manually forced to start. Chiller will start regardless of time schedule or remote contact status.

C. IN RECYCLE SHUTDOWN

PRIMARY MESSAGE SECONDARY MESSAGE PROBABLE CAUSE/REMEDY

RECYCLE RESTART PENDING OCCUPIED MODE RECYCLE RESTART PENDING REMOTE CONTACT CLOSED RECYCLE RESTART PENDING START COMMAND IN EFFECT RECYCLE RESTART PENDING ICE BUILD MODE

Unit in recycle mode, chilled water temperature is not high enough to start.

Chiller START/STOP on STATUS01 manually forced to start, chilled water temperature is not high enough to start.

Chiller in ICE BUILD mode. Chilled water/brine temperature is satis-

ICE BUILD SETPOINT

ﬁed for

temperature.

Page 87

Table 12 — LID Primary and Secondary Messages and Custom Alarm/Alert Messages

with Troubleshooting Guides (cont)

D. PRE-STARTALERTS: These alerts only delay start-up. When alert is corrected, the start-up will continue. No reset is necessary.

PRIMARY MESSAGE SECONDARY MESSAGE ALARM MESSAGE/PRIMARY CAUSE ADDITIONAL CAUSE/REMEDY PRESTART ALERT STARTS LIMIT EXCEEDED STARTS EXCESSIVE Compressor Starts (8 in

PRESTART ALERT HIGH MOTOR TEMPERATURE MTRW [VALUE] exceeded limit of [LIMIT]*.

PRESTART ALERT HIGH BEARING TEMPERATURE MTRB [VALUE] exceeded limit of [LIMIT]*.

PRESTART ALERT HIGH DISCHARGE TEMP CMPD [VALUE] exceeded limit of [LIMIT]*. PRESTART ALERT LOW REFRIGERANT TEMP ERT [VALUE] exceeded limit of [LIMIT]*. Check PRESTART ALERT LOW OIL TEMPERATURE OILT [VALUE] exceeded limit of [LIMIT]*. PRESTART ALERT LOW LINE VOLTAGE V P [VALUE] exceeded limit of [LIMIT]*.

PRESTART ALERT HIGH LINE VOLTAGE V P [VALUE] exceeded limit of [LIMIT]*.

PRESTART ALERT HIGH CONDENSER PRESSURE CRP [VALUE] exceeded limit of [LIMIT]*. Check PRESTART ALERT HIGH GEAR OIL TEMP GEAOILT [VALUE] exceeded limit of [LIMIT].*

*[LIMIT] is shown on the LID as temperature, pressure, voltage, etc., set point predeﬁned or selected by the operator as an override, alert, or alarm condition. [VALUE]

is the actual pressure, temperature, voltage, etc., at which the control tripped.

12 hours) Check motor temperature.

Check thrust bearing temperature.

Check discharge temperature. refrigerant temperature. Check oil temperature. Check voltage supply.

Check voltage supply.

condenser water and transducer. Check gear oil cooler ﬂow.

E. NORMAL OR AUTO.-RESTART

Depress the RESET softkey if additionalstart is required. Reassess start-up requirements.

Check motor cooling line for proper operation. Check for excessive starts within a short time span.

Check oil heater for properoperation, check for low oil level, partially closed oil supply valves, etc. Check sensor accuracy.

Check sensor accuracy. Allow discharge temperature to cool. Check for excessive starts.

Checktransducer accuracy.Checkfor low chilled water/brine supply temperature.

Check oil heater power, oil heater relay. Check oil level.

Checkvoltage supply.Check voltage transformers. Consult power utility if voltage is low.Calibrate voltage reading on STATUS01 Table.

Checkvoltage supply.Check voltage transformers. Consult power utility if voltage is low.Calibrate voltage reading on STATUS01 table.

Check for high condenser water temperature. Check transducer accuracy.

Check for cooler water ﬂow. Check sensor for accuracy.

PRIMARY MESSAGE SECONDARY MESSAGE PROBABLE CAUSE/REMEDY

STARTUP IN PROGRESS OCCUPIED MODE Chiller starting. Time schedule is occupied. STARTUP IN PROGRESS REMOTE CONTACT CLOSED Chiller starting. Remote contacts are closed.

STARTUP IN PROGRESS START COMMAND IN EFFECT AUTORESTART IN PROGRESS OCCUPIED MODE Chiller starting. Time schedule is occupied.

AUTORESTART IN PROGRESS REMOTE CONTACT CLOSED Chiller starting. Remote contacts are closed. AUTORESTART IN PROGRESS START COMMAND IN EFFECT

Chiller starting. Chiller START/STOP on STATUS01 manually forced to start.

F. SPARE SENSOR ALERT MESSAGES

PRIMARY MESSAGE SECONDARY MESSAGE ALARM MESSAGE/PRIMARY CAUSE ADDITIONAL CAUSE/REMEDY

SPARE SENSOR ALERT COMMON CHWS SENSOR Sensor Fault: Check commonCHWS sensor. SPARE SENSOR ALERT COMMON CHWR SENSOR Sensor Fault: Check common CHWR

SPARE SENSOR ALERT REMOTE RESET SENSOR Sensor Fault: Check remote reset tempera- SPARE SENSOR ALERT TEMP SENSOR — SPARE 1 Sensor Fault: Check temperature sensor — SPARE SENSOR ALERT TEMP SENSOR — SPARE 2 Sensor Fault: Check temperature sensor — SPARE SENSOR ALERT TEMP SENSOR — SPARE 3 Sensor Fault: Check temperature sensor — SPARE SENSOR ALERT TEMP SENSOR — SPARE 4 Sensor Fault: Check temperature sensor — SPARE SENSOR ALERT TEMP SENSOR — SPARE 5 Sensor Fault: Check temperature sensor — SPARE SENSOR ALERT TEMP SENSOR — SPARE 6 Sensor Fault: Check temperature sensor — SPARE SENSOR ALERT TEMP SENSOR — SPARE 7 Sensor Fault: Check temperature sensor — SPARE SENSOR ALERT TEMP SENSOR — SPARE 8 Sensor Fault: Check temperature sensor — SPARE SENSOR ALERT TEMP SENSOR — SPARE 9 Sensor Fault: Check temperature sensor —

sensor. ture sensor. Spare 1. Spare 2. Spare 3. Spare 4. Spare 5. Spare 6. Spare 7. Spare 8. Spare 9.

Check alert temperature set points on EQUIPMENT SERVICE table, SERVICE2 screen. Check sensor for accuracy if reading is not accurate.

Page 88

Table 12 — LID Primary and Secondary Messages and Custom Alarm/Alert Messages

with Troubleshooting Guides (cont)

G. START-UP FAILURES: This is an alarm condition. A manual reset is required to clear.

PRIMARY MESSAGE SECONDARY MESSAGE ALARM MESSAGE/PRIMARY CAUSE ADDITIONAL CAUSE/REMEDY FAILURE TO START LOW OIL PRESSURE OILPD [VALUE] exceeded limit of [LIMIT]*. Check

FAILURE TO START OIL PRESS SENSOR FAULT OILPD [VALUE] exceeded limit of [LIMIT]*. Check

FAILURE TO START LOW CHILLED WATER FLOW EVFL Evap Flow Fault: Check water pump/ﬂow FAILURE TO START LOW CONDENSER FAILURE TO START STARTER FAULT STR FLT Starter Fault: Check Starter for Fault FAILURE TO START STARTER OVERLOAD TRIP STR FLT Starter Overload Trip: Check amps FAILURE TO START LINE VOLTAGE DROPOUT V P Single-Cycle Dropout Detected: Check volt-

FAILURE TO START HIGH CONDENSER

FAILURE TO START EXCESS ACCELERATION

FAILURE TO START STARTER TRANSITION FAILURE TO START 1CR AUX CONTACT FAULT 1CR AUX Starter Contact Fault: Check 1CR/1M FAILURE TO START MOTOR AMPS NOT SENSED CA PMotor Amps Not Sensed:Check motor load

FAILURE TO START CHECK REFRIGERANT TYPE Current Refrigerant PropertiesAbnormal — Check

FAILURE TO START LOW OIL PRESSURE LowOilPressure [LIMIT]:*Check oilpressure switch/

FAILURE TO START LOW GEAR OIL PRESSURE GEAROILP [VALUE] exceeded limit of [LIMIT].* FAILURE TO START GEAR OIL PRESSURE SENSOR Gear OilPressureTransducer Out ofRange [VALUE]. Check calibration of transducer. Replace if

*[LIMIT] is shown on the LID as the temperature, pressure, voltage, etc., set pointpredeﬁned or selectedby the operatoras an override,alert, or alarmcondition. [VALUE]

is the actual pressure, temperature, voltage, etc., at which the control tripped.

WATER FLOW

PRESSURE

TIME

FAULT

oil pump system.

oil pressure sensor.

switch. CDFL Cond. Flow Fault: Check water pump/ﬂow

switch. Source. calibration/reset overload. age supply.

High Condenser Pressure [LIMIT]:* Check switch 2C aux, and water temperature/ﬂow.

CA P ExcessAcceleration:Check guidevane closure at start-up.

RUN AUX Starter Transition Fault: Check 1CR/ 1M/Interlock mechanism.

aux. contacts. signal.

Selection of refrigerant type.

pump and 2C aux.

Check gear oil pump/ﬁlter.

Check for closed oil supply valves. Check oil ﬁlter. Check for low oil temperature. Check transducer accuracy.

Check for excessive refrigerant in oil sump. Run oil pump manually for 5 minutes. Check calibration of oilpressure differentialampliﬁer modules.Check wiring. Replace transducers if necessary.

Check wiring to ﬂow switch. Check through CONTROL TEST for proper switch operation.

Astarter protective device has faulted. Check starter for ground fault, voltage trip, temperature trip, etc.

Reset overloads, check ICR relay before restarting chiller.

Check voltage supply.Check transformers for supply.Checkwith utilityif voltagesupply is erratic. Monitor must be installed to conﬁrm consistent, singlecycle dropouts. Check low oil pressure switch.

Check for proper design condenser ﬂow and temperature.Check condenserapproach. Check 2Cauxiliary contactson oil sump starter. Check high pressure switch.

Checkthat guidevanes areclosed atstart-up. Check starter for proper operation. Reduce unit pressure if possible.

Check starter for proper operation. Run contact failed to close.

Check starter for proper operation. Start contact failed to close.

Checkfor proper motor amps signal to SMM.Check wiringfrom SMMto current transformer. Check main motor circuit breaker for trip.

Pressures at transducers indicate another refrigerant type in control test. Makesure toaccess the ATTACHTO NETWORK DEVICE screen after specifying HFC-134a refrigerant type.

The oil pressure differential switch is open when the compressortried tostart. Checkthe switchfor proper operation.Also,check theoil pumpinterlock (2Caux) in the power panel and the high condenser pressure switch.

Check for closed oil supply valves. Check oil ﬁlter. Check transducer accuracy.

necessary.

H. COMPRESSOR JUMPSTARTAND REFRIGERANT PROTECTION

PRIMARY MESSAGE SECONDARY MESSAGE ALARM MESSAGE/PRIMARY CAUSE ADDITIONAL CAUSE/REMEDY

UNAUTHORIZED OPERATION

POTENTIAL FREEZE-UP EVAP PRESS/TEMP

FAILURE TO STOP DISCONNECT POWER RUN AUX Emergency: DISCONNECT

LOSS OF COMMUNICATION

STARTER CONTACT FAULT

POTENTIAL FREEZE UP COND PRESS/TEMP

*[LIMIT] is shown on the LID as the temperature, pressure, voltage, etc., set pointpredeﬁned or selectedby the operatoras an override,alert, or alarmcondition. [VALUE]

is the actual pressure, temperature, voltage, etc., at which the control tripped.

UNIT SHOULD BE STOPPED

TOO LOW

WITH STARTER Loss of Communication with Starter: Check ABNORMAL 1CR OR

RUN AUX TOO LOW

CA P Emergency: Compressor running without control authorization.

ERT Emergency: Freeze-up prevention.

POWER.

chiller. 1CR AUX Starter Contact Fault: Check

1CR/1M aux. contacts. CRT [VALUE] exceeded limit of [LIMIT]*

Emergency: Freeze-up prevention.

Compressor is running with more than 10% RLA and control is trying to shut it down. Turn power offto compressorif unable tostop. Determinecause before re-powering.

Determine cause. If pumping refrigerant out of chiller, stop operation and go over pumpout procedures.

Starter run and startcontacts are energized while control tried to shut down. Disconnect power to starter.

Checkwiring fromPSIO to SMM.Check SMMmodule troubleshooting procedures.

Starterrun andstart contacts energizedwhile chiller was off. Disconnect power.

The condenser pressure transducer is reading a pressure that could freeze the water in the condensertubes. Checkforcondenser refrigerantleaks, bad transducers,or transferred refrigerant. Place the unit in PUMPDOWN mode to eliminate the alarm if vessel is evacuated.

Page 89

Table 12 — LID Primary and Secondary Messages and Custom Alarm/Alert Messages

with Troubleshooting Guides (cont)

I. NORMAL RUN WITH RESET, TEMPERATURE, OR DEMAND

PRIMARY MESSAGE SECONDARY MESSAGE PROBABLE CAUSE/REMEDY

RUNNING — RESET ACTIVE 4-20MA SIGNAL

RUNNING — RESET ACTIVE CHW TEMP DIFFERENCE RUNNING — TEMP CONTROL LEAVING CHILLED WATER Default method of temperature control. RUNNING — TEMP CONTROL ENTERING CHILLED WATER ECW control activated on CONFIG screen. RUNNING — TEMP CONTROL TEMPERATURE RAMP LOADING Ramp loading in effect. Use SERVICE1 screen to modify. RUNNING — DEMAND LIMITED BY DEMAND RAMP LOADING Ramp loading in effect. Use SERVICE1 screen to modify. RUNNING — DEMAND LIMITED BY LOCAL DEMAND SETPOINT Demand limit set point is , actual demand. RUNNING — DEMAND LIMITED BY 4-20MA SIGNAL

RUNNING — DEMAND LIMITED BY LOADSHED/REDLINE RUNNING — TEMP CONTROL HOT GAS BYPASS RUNNING — DEMAND LIMITED BY LOCAL SIGNAL Active demand limit manually overridden on STATUS01 table.

RUNNING — TEMP CONTROL ICE BUILD MODE Chiller is running under Ice Build temperature control.

J. NORMAL RUN OVERRIDES ACTIVE (ALERTS)

PRIMARY MESSAGE SECONDARY MESSAGE ALARM MESSAGE/PRIMARY CAUSE ADDITIONAL CAUSE/REMEDY

RUN CAPACITY LIMITED HIGH CONDENSER PRESSURE CRP [VALUE] exceeded limit of [LIMIT]*. RUN CAPACITY LIMITED HIGH MOTOR TEMPERATURE MTRW [VALUE] exceeded limit of [LIMIT]*. RUN CAPACITY LIMITED LOW EVAP REFRIG TEMP ERT[VALUE]exceeded limit of [LIMIT]*. Check RUN CAPACITY LIMITED HIGH COMPRESSOR LIFT Surge Prevention Override; lift too high for RUN CAPACITY LIMITED MANUAL GUIDE VANE TARGET GV TRGRun Capacity Limited: Manual guide

*[LIMIT] is shown on the LID as the temperature, pressure, voltage, etc., set pointpredeﬁned or selectedby the operatoras an override,alert, or alarmcondition. [VALUE]

is the actual temperature, pressure, voltage, etc., at which the control tripped.

Condenser pressure override. Motor temperature override. refrigerant charge level. compressor. vane target.

Reset program active based on CONFIG screen setup.RUNNING — RESET ACTIVE REMOTE SENSOR CONTROL

Demand limit is active based on CONFIG screen setup.RUNNING — DEMAND LIMITED BY CCN SIGNAL

Hot gas bypass option is energized. See surge prevention in the control section.

See Capacity Overrides, Table 4. Correct operating condition, modify setpoint, or release override.

K. OUT-OF-RANGE SENSOR FAILURES

PRIMARY MESSAGE SECONDARY MESSAGE ALARM MESSAGE/PRIMARY CAUSE ADDITIONAL CAUSE/REMEDY SENSOR FAULT LEAVING CHW TEMPERATURE Sensor Fault: Check leaving CHW

SENSOR FAULT ENTERING CHW TEMPERATURE Sensor Fault: Check entering CHW SENSOR FAULT CONDENSER PRESSURE Sensor Fault: Check condenser pressure SENSOR FAULT EVAPORATOR PRESSURE Sensor Fault: Check evaporator pressure SENSOR FAULT BEARING TEMPERATURE Sensor Fault: Check bearing temperature SENSOR FAULT MOTOR WINDING TEMP Sensor Fault: Check motor temperature SENSOR FAULT DISCHARGE TEMPERATURE Sensor Fault: Check discharge temperature SENSOR FAULT OIL SUMP TEMPERATURE Sensor Fault: Check oil sump temperature SENSOR FAULT OIL PRESSURE TRANSDUCER Sensor Fault: Check oil pressure

sensor. sensor. transducer. transducer. sensor. sensor. sensor. sensor. transducer.

See sensor test procedure and check sensors for proper operation and wiring.

Page 90

Table 12 — LID Primary and Secondary Messages and Custom Alarm/Alert Messages

with Troubleshooting Guides (cont)

L. CHILLER PROTECT LIMIT FAULTS

Excessive numbers of the same fault can lead to severe chiller damage. Seek service expertise.

PRIMARY MESSAGE SECONDARY MESSAGE ALARM MESSAGE/PRIMARY CAUSE ADDITIONAL CAUSE/REMEDY PROTECTIVE LIMIT HIGH DISCHARGE TEMP CMPD [VALUE] exceeded limit of [LIMIT]*.

PROTECTIVE LIMIT LOW REFRIGERANT TEMP ERT [VALUE] exceeded limit of [LIMIT]*.

PROTECTIVE LIMIT HIGH MOTOR TEMPERATURE MTRW [VALUE]exceeded limit of [LIMIT]*.

PROTECTIVE LIMIT HIGH BEARING TEMPERATURE MTRB [VALUE] exceeded limit of [LIMIT]*.

PROTECTIVE LIMIT LOW OIL PRESSURE OILPD [VALUE] exceeded limit of [LIMIT]*.

PROTECTIVE LIMIT NO MOTOR CURRENT CA P Loss of Motor Current: Check

PROTECTIVE LIMIT POWER LOSS V P Power Loss: Check voltage PROTECTIVE LIMIT LOW LINE VOLTAGE V P [VALUE] exceeded limit of [LIMIT]*. PROTECTIVE LIMIT HIGH LINE VOLTAGE V P [VALUE] exceeded limit of [LIMIT]*. PROTECTIVE LIMIT LOW CHILLED WATER FLOW EVFL Flow Fault: Check evap pump/ﬂow PROTECTIVE LIMIT LOW CONDENSER WATER FLOW CDFL Flow Fault: Check condenser pump/ PROTECTIVE LIMIT HIGH CONDENSER PRESSURE High CondPressure [OPEN]*:Check switch,

PROTECTIVE LIMIT HIGH CONDENSER PRESSURE HighCond Pressure [VALUE]*:Checkswitch,

PROTECTIVE LIMIT 1CR AUX CONTACT FAULT CR AUX Starter Contact Fault: Check PROTECTIVE LIMIT RUN AUX CONTACT FAULT RUN AUX Starter Contact Fault: Check PROTECTIVE LIMIT CCN OVERRIDE STOP CHIL S S CCN Override Stop while in

PROTECTIVE LIMIT SPARE SAFETY DEVICE SRP PL Spare Safety Fault: Check PROTECTIVE LIMIT EXCESSIVE MOTOR AMPS CA P [VALUE]exceeded limit of [LIMIT]*. PROTECTIVE LIMIT EXCESSIVE COMPR SURGE Compressor Surge: Check condenser wa- PROTECTIVE LIMIT STARTER FAULT STR FLT Starter Fault: Check starter for

PROTECTIVE LIMIT STARTER OVERLOAD TRIP STR FLT Starter Overload Trip: Check

*[LIMIT] is shown on the LID as the temperature, pressure, voltage, etc., set point predeﬁned or selected by the

operator as an override, alert, or alarm condition. [VALUE] is the actual temperature, pressure, voltage, etc., at which the control tripped. [OPEN] indicates that an input circuit is open.

Check discharge temperature.

Check evap pump and ﬂow switch.

Check motor cooling and solenoid.

Check oil cooling control.

Check oil pump and transducer.

Low Oil Pressure [OPEN]*. Check oil pressure switch/pump and 2C aux.

sensor.

supply. Check voltage supply. Check voltage supply. switch. ﬂow switch. oil pressure contact, and water temp/ﬂow.

HighCond Pressure[VALUE]*:Checkswitch, water ﬂow, and transducer.

water ﬂow, and transducer.

1CR/1M aux contacts. 1CR/1M aux contacts. LOCAL run mode.

contacts. High Amps; Check guide vane drive. ter temp and ﬂow.

fault source.

amps calibration/reset overload.

Checkdischarge temperatureimmediately.Check sensor for accuracy; check for propercondenser ﬂowand temperature; check oil reservoir temperature. Check condenser for fouled tubes or air in chiller. Check for proper guide vane actuator operation.

Check for proper amount of refrigerant charge; check for proper water ﬂow and temperatures. Check for proper guide vane actuator operation.

Check motor temperature immediately. Check sensorfor accuracy.Checkfor proper condenser ﬂow and temperature. Check motor cooling system for restrictions. Check motor coolingsolenoid for proper operation. Check refrigerant ﬁlter.

Check for throttled oil supply isolation valves. Valves should be wide open. Check oil cooler thermal expansion valve. Check sensor accuracy. Check journaland thrust bearings. Check refrigerant ﬁlter.Check for excessive oil sump level.

Check powerto oil pump and oil level. Check for dirty ﬁltersor oilfoaming atstart-up. Checkfor thermaloverload cutout. Reduce ramp load rate if foaming noted. NOTE: This alarm is not related to pressure switch problems.

Check the oil pressure switch for proper operation. Check oil pump for proper pressure. Check for excessive refrigerant in oil system.

Checkwiring: Checktorque setting onsolid-state starter. Check for main circuit breaker trip. Check power supply to PSIO module.

Check 24-vac input on the SMM (terminals 23 and

24).Check transformersto SMM. Check power toPSIO module. Check distribution bus. Consult power company.

Perform pumps control test (from CONTROL TEST table) and verify proper switch operation. Check all water valves and pump operation.

Checkthe high-pressureswitch. Checkfor propercondenser pressures and condenser water ﬂow. Check for fouled tubes. Check the 2C aux. contact and the oil pressure switch in the power panel. This alarm is not caused by the transducer.

Checkwater ﬂowin condenser.Checkfor fouledtubes. Transducershould be checkedfor accuracy.Thisalarm is not caused by the high pressure switch.

1CR auxiliary contact opened while chiller was running. Check starter for proper operation.

Run auxiliary contact opened while chiller was running. Check starter for proper operation.

CCN has signaled chiller to stop. Reset and restart when ready. Ifthe signal wassent by the LID, release the Stop signal on STATUS01 table.

Sparesafety inputhastripped orfactory-installed jumper not present.

Checkmotor currentfor proper calibration. Check guide vane drive and actuator for proper operation.

Check condenser ﬂow and temperatures. Checkconﬁguration of surge protection.

Check starter for possible ground fault, reverse rotation, voltage trip, etc.

Reset overloads and reset alarm. Check motor current calibration or overload calibration (do not ﬁeldcalibrate overloads).

Page 91

Table 12 — LID Primary and Secondary Messages and Custom Alarm/Alert Messages

with Troubleshooting Guides (cont)

L. CHILLER PROTECT LIMIT FAULTS (cont)

Excessive numbers of the same fault can lead to severe chiller damage. Seek service expertise.

PRIMARY MESSAGE SECONDARY MESSAGE ALARM MESSAGE/PRIMARY CAUSE ADDITIONAL CAUSE/REMEDY PROTECTIVE LIMIT TRANSDUCER VOLTAGE FAULT V REF [VALUE]exceededlimit of[LIMIT]*.

PROTECTIVE LIMIT LOW GEAR OIL PRESSURE GEAROILP [VALUE] exceeded imit of PROTECTIVE LIMIT HIGH GEAR OIL TEMP GEAOILT [VALUE] exceeded limit of PROTECTIVE LIMIT CCN OVERRIDE STOP CHIL S S CCN. Override stop while in

*[LIMIT] is shown on the LID as the temperature, pressure, voltage, etc., set point predeﬁned or selected by

the operator as an override, alert, or alarm condition. [VALUE] is the actual temperature, pressure, voltage, etc., at which the control tripped. [OPEN] indicates that an input circuit is open.

Check transducer power supply. [LIMIT]*. Check gear oil pump ﬁlter. [LIMIT]*. Check gear oil cooler ﬁlter.

local run mode.

Check transformer power (5 vdc) supply to transducers. Power must be 4.5 to 5.5 vdc.

Check for closed oil supply valves. Checkoil ﬁlter. Check transducer accuracy.

Check for cooler water ﬂow. Check sensor for accuracy.

Machine received a command from the network to stop overriding local operating mode.

M. CHILLER ALERTS

PRIMARY MESSAGE SECONDARY MESSAGE ALARM MESSAGE/PRIMARYCAUSE ADDITIONAL CAUSE/REMEDY

RECYCLE ALERT HIGH AMPS AT SHUTDOWN High Amps atRecycle: Checkguide vane

SENSOR FAULT ALERT LEAVING COND WATER TEMP SensorFault: Checkleaving condenser SENSOR FAULT ALERT ENTERING COND WATER TEMP Sensor Fault: Check entering condenser

LOW OIL PRESSURE ALERT

AUTORESTART PENDING POWER LOSS V P Power Loss: Check voltage AUTORESTART PENDING LOW LINE VOLTAGE V P[VALUE]exceeded limit of[LIMIT]*. AUTORESTART PENDING HIGH LINE VOLTAGE V P[VALUE]exceeded limitof [LIMIT]*. SENSOR ALERT HIGH DISCHARGE TEMP CMPD [VALUE] exceeded limit of

SENSOR ALERT HIGH BEARING TEMP MTRB [VALUE] exceeded limit of

CONDENSER PRESSURE ALERT

RECYCLE ALERT EXCESSIVE RECYCLE STARTS Excessive recycle starts. The chiller loadis toosmall tokeep thechiller

SENSOR ALERT LOW GEAR OIL PRESSURE GEAROILP [VALUE] exceeded imit of SENSOR ALERT HIGH GEAR OIL TEMP GEAOILT [VALUE] exceeded limit of

*[LIMIT] is shown on the LID as the temperature, pressure, voltage, etc., set point predeﬁned or selected by

the operator as an override, alert, or alarm condition. [VALUE] is the actual temperature, pressure, voltage, etc., at which the control tripped.

CHECK OIL FILTER Low Oil Pressure Alert: Check oil Check oil ﬁlter.Check for improper oil level

PUMP RELAY ENERGIZED CRPHighCondenser Pressure [LIMIT]*.

drive.

water sensor. water sensor.

supply. Check voltage supply. Check voltage supply. [LIMIT]*. Check discharge

temperature. [LIMIT]*. Check thrust bearing

temperature. Pump energized to reduce pressure.

[LIMIT]*. Check gear oil pump ﬁlter. [LIMIT]*. Check gear oil cooler ﬁlter.

Check that guide vanes are closing. Check motor amps correction calibration is correct. Check actuator for proper operation.

Check sensor. See sensor test procedure.

or temperature. Check power supply if there are excessive

compressor starts occurring.

Discharge temperature exceeded the alert threshold. Check entering condenser water temperature.

Thrust bearing temperature exceeded the alert threshold. Check for closed valves,improper oil level or temperatures.

Check ambient conditions. Check condenser pressure for accuracy.

on line and there have been more than 5 restarts in 4 hours. Increase chillerload, adjusthot gasbypass, increase

START DELTA T

Check for closed oil supply valves. Check oil ﬁlter. Check transducer accuracy.

Check for cooler water ﬂow. Check sensor for accuracy.

from SERVICE1 screen.

RECYCLERE-

Page 92

Table 12 — LID Primary and Secondary Messages and Custom Alarm/Alert Messages

with Troubleshooting Guides (cont)

N. OTHER PROBLEMS/MALFUNCTIONS

DESCRIPTION/MALFUNCTION PROBABLE CAUSE/REMEDY

Chilled Water/Brine Temperature Too High (Chiller Running)

Chilled Water/Brine Temperature Too Low (Chiller Running)

Chilled Water Temperature Fluctuates. Vanes Hunt Deadband toonarrow.Conﬁgure LID fora largerdeadband (SERVICE1screen).

Low Oil Sump Temperature While Running (Less than 100 F [38 C])

AtPower Up, DefaultScreen DoesNot Appear,‘‘TablesLoading’’ Message Continually Appears

SMM Communications Failure Check thatPSIO communication plugs areconnectedcorrectly.Check SMM

High Oil Temperature While Running Check for proper oil level (too much oil). Check water supply to oil cooler. Blank LID Screen (Minimal Contrast Visible) Increase contrast potentiometer. See Fig. 49. Check red LED on LID for

‘‘Communications Failure’’ Highlighted Message At Bottom of LID Screen

Control Test Disabled Press the Stop pushbutton. The PIC must be in the OFF mode for the con-

Vanes Will Not Open in Control Test Low pressure alarm is active. Put chiller into PUMPDOWN mode or equal- Oil Pump Does Not Run Check oil pump voltage supply. Cooler vessel pressure under vacuum. LID Default Screen Does Not Update This is normal operation when an alarm is present. The screen freezes the

Chiller Does Not Stop When the STOP Button is Pressed The STOP button wiring connector on the LID module is not properly con-

LID Screen Dark Light bulb burned out. Replace as needed.

Chilled water set point set too high. Access set point on LID and verify. Capacityoverride or excessive coolingload (chiller atdesigncapacity). Check

LIDstatusmessages. Check foroutsideair inﬁltration intoconditioned space. Condenser temperature too high. Check for proper ﬂow, examine cooling

tower operation, check for air or water leaks, check for fouled tubes. Refrigerant level low. Check for leaks, add refrigerant, and trim charge. Liquid bypass in waterbox. Examine division plates and gaskets for leaks. Guide vanes fail to open. Use control test to check operation. Chilled water control point too high. Access CONTROL ALGORITHM STA-

TUS table, MAINT01 screen, and check chilled water control operation. Guide vanesfailto open fully.Be sure that the guide vanetargetis released.

Check guide vane linkage. Check limit switch in actuator.Check that sensor is in the proper terminals.

Chilled water set point set too low. Access set point on LID and verify. Chilled water control point too low. Access CONTROL ALGORITHM STA-

TUS tables, MAINT01 screen, and check chilled water control for proper resets.

High discharge temperature keeps guide vanes open. Guide vanes fail to close. Be sure that guide vane target is released. Check

chilled water sensor accuracy. Check guide vane linkage. Check actuator operation.

Proportional bandstoo narrow.Either

PORTIONAL DEC BAND

Loose guide vane drive. Adjust chain drive. Defective vane actuator. Check using control test feature. Defective temperature sensor. Check sensor accuracy. Check for proper oil level (not enough oil).

Check for proper communications wiring on PSIO module. Check that the COMM1 communications wires from the LID are terminated to the COMM1 PSIO connection. Check for ground or short on CCN system wiring.

communicationplug.Check for proper SMMpower supply.See Control Modules section on page 96.

proper operation, (power supply). If LED is blinking, but green LED’s are not, replace LID module, (memory failure). Check light bulb if backlit model.

LID is not properly addressed to the PSIO. Make sure that, on ATTACH TO NETWORK DEVICE screen,. dress.CheckLEDs on PSIO. Isred LED operating properly?Are greenLEDs blinking? See Control Module troubleshooting section.

trol test feature to operate. Clear all alarms. Check line voltage percent on STATUS01 screen. The percent must be within 90% to 110%. Check voltage input to SMM; calibrate starter voltage potentiometer for accuracy.

ize pressure. Check guide vane actuator wiring. Pressurize vessel. Check temperature overload cutout switch. momentthe alarm isactivated to aidin troubleshooting. TheSTA TUS01screen

provides current information. nected or the chiller is in soft stop mode and the guide vanes are

closing.

should be increased (MAINT01 screen).

PROPORTIONALINC BANDorPRO-

LOCAL DEVICE

is set to read the PSIO ad-

Page 93

Table 13 — External Gear Troubleshooting Guide

PROBLEM POSSIBLE CAUSE — ITEM NO.s*

Excessive Operating Temperature 1,2,3,4,5,6,7,9,12,18,20,21 Oil Leakage 1,2,3,4,5,7,9,12,13,18,19,21 Gear Wear 1,2,3,4,6,7,8,9,10,11,12,13,14,15,16,18,19,21,22 Bearing Failure 1,6,7,8,9,10,11,12,15,16,19,20,21 Unusual Noise 1,2,3,4,6,7,8,9,10,11,12,13,15,16,17,20,21

*See table below for probable cause and suggested remedy.

POSSIBLE CAUSE ACTION

1. Unit Overload Reduce the loading.

2. Incorrect Oil Level Verify that the oil level is correct. Too little or too much oil can cause high

3. Wrong Oil Grade Use only the AGMA (American Gear Manufacturers Association) grade oil

4. Contaminated Oil If oil is oxidized, dirty, or has high sludge content, change the oil.

5. Clogged Breather Clean breather regularly.

6. Improper Bearing Clearance Too large or too small bearing clearance. Refer to drawing or contact the

7. Improper Coupling Alignment Disconnect couplings, check spacing between shafts, and check alignment.

8. Incorrect Coupling Rigid couplings can cause shaft failure. Replace with a coupling that pro-

9. Excessive Operating Speed Reduce the speed.

10. Torsional or Lateral Vibrations Vibrations can occur through a particular speed range known as the critical

11. Extreme Repetitive Shocks Apply couplings capable of absorbing shocks.

12. Improper Lubrication of Bearings Verify that all bearings are receiving adequate amounts of lubricating oil.

13. Improper Storage or Prolonged Shutdown Destructive rusting of bearings and gears will be caused by storage or pro-

14. Excessive Backlash Contact gear manufacturer.

15. Misalignment of Gears Contact pattern to be a minimum of 80% of face.

16. Housing Twisted or Distorted Verify proper shimming or stiffness of the foundation.

17. Gear Tooth Wear Contact gear manufacturer.

18. Open Drains Tighten drain plugs.

19. Loosely Bolted Covers Check all bolted joints and tighten if necessary.

20. Motor Related Verifythat actual operating conditions are consistent with motor nameplate.

21. Excessive Ambient Temperature Shield unit from heat source and maintain proper air ﬂow around the gear

temperature. as speciﬁed for the unit size and ambient temperature.

gear manufacturer for correct clearance, checking technique, and tolerance. Shafts should turn freely when disconnected from the load.

Realign as required. vides ﬂexibility and lateral ﬂoat.

speed. Contact the factory for speciﬁc recommendations.

longed shutdown in moist ambient temperatures. If rust is found, unit must be disassembled, inspected, and repaired.

unit.

Page 94

Table 14A — Thermistor Temperature (F) vs Resistance/Voltage Drop

TEMPERATURE VOLTAGE RESISTANCE

(F) DROP (V) (Ohms)

−25.0 4.821 98010

−24.0 4.818 94707

−23.0 4.814 91522

−22.0 4.806 88449

−21.0 4.800 85486

−20.0 4.793 82627

−19.0 4.786 79871

−18.0 4.779 77212

−17.0 4.772 74648

−16.0 4.764 72175

−15.0 4.757 69790

−14.0 4.749 67490

−13.0 4.740 65272

−12.0 4.734 63133

−11.0 4.724 61070

−10.0 4.715 59081

−9.0 4.705 57162

−8.0 4.696 55311

−7.0 4.688 53526

−6.0 4.676 51804

−5.0 4.666 50143

−4.0 4.657 48541

−3.0 4.648 46996

−2.0 4.636 45505

−1.0 4.624 44066

0.0 4.613 42679

1.0 4.602 41339

2.0 4.592 40047

3.0 4.579 38800

4.0 4.567 37596

5.0 4.554 36435

6.0 4.540 35313

7.0 4.527 34231

8.0 4.514 33185

9.0 4.501 32176

10.0 4.487 31202

11.0 4.472 30260

12.0 4.457 29351

13.0 4.442 28473

14.0 4.427 27624

15.0 4.413 26804

16.0 4.397 26011

17.0 4.381 25245

18.0 4.366 24505

19.0 4.348 23789

20.0 4.330 23096

21.0 4.313 22427

22.0 4.295 21779

23.0 4.278 21153

24.0 4.258 20547

25.0 4.241 19960

26.0 4.223 19393

27.0 4.202 18843

28.0 4.184 18311

29.0 4.165 17796

30.0 4.145 17297

31.0 4.125 16814

32.0 4.103 16346

33.0 4.082 15892

34.0 4.059 15453

35.0 4.037 15027

36.0 4.017 14614

37.0 3.994 14214

38.0 3.968 13826

39.0 3.948 13449

40.0 3.927 13084

41.0 3.902 12730

42.0 3.878 12387

43.0 3.854 12053

44.0 3.828 11730

45.0 3.805 11416

46.0 3.781 11112

47.0 3.757 10816

48.0 3.729 10529

49.0 3.705 10250

50.0 3.679 9979

51.0 3.653 9717

52.0 3.627 9461

53.0 3.600 9213

54.0 3.575 8973

55.0 3.547 8739

56.0 3.520 8511

57.0 3.493 8291

58.0 3.464 8076

59.0 3.437 7868

60.0 3.409 7665

61.0 3.382 7468

62.0 3.353 7277

63.0 3.323 7091

64.0 3.295 6911

65.0 3.267 6735

66.0 3.238 6564

67.0 3.210 6399

68.0 3.181 6238

69.0 3.152 6081

70.0 3.123 5929

TEMPERATURE VOLTAGE RESISTANCE

(F) DROP (V) (Ohms)

71 3.093 5781 72 3.064 5637 73 3.034 5497 74 3.005 5361 75 2.977 5229 76 2.947 5101 77 2.917 4976 78 2.884 4855 79 2.857 4737 80 2.827 4622 81 2.797 4511 82 2.766 4403 83 2.738 4298 84 2.708 4196 85 2.679 4096 86 2.650 4000 87 2.622 3906 88 2.593 3814 89 2.563 3726 90 2.533 3640 91 2.505 3556 92 2.476 3474 93 2.447 3395 94 2.417 3318 95 2.388 3243 96 2.360 3170 97 2.332 3099 98 2.305 3031

99 2.277 2964 100 2.251 2898 101 2.217 2835 102 2.189 2773 103 2.162 2713 104 2.136 2655 105 2.107 2597 106 2.080 2542 107 2.053 2488 108 2.028 2436 109 2.001 2385 110 1.973 2335 111 1.946 2286 112 1.919 2239 113 1.897 2192 114 1.870 2147 115 1.846 2103 116 1.822 2060 117 1.792 2018 118 1.771 1977 119 1.748 1937 120 1.724 1898 121 1.702 1860 122 1.676 1822 123 1.653 1786 124 1.630 1750 125 1.607 1715 126 1.585 1680 127 1.562 1647 128 1.538 1614 129 1.517 1582 130 1.496 1550 131 1.474 1519 132 1.453 1489 133 1.431 1459 134 1.408 1430 135 1.389 1401 136 1.369 1373 137 1.348 1345 138 1.327 1318 139 1.308 1291 140 1.291 1265 141 1.289 1240 142 1.269 1214 143 1.250 1190 144 1.230 1165 145 1.211 1141 146 1.192 1118 147 1.173 1095 148 1.155 1072 149 1.136 1050 150 1.118 1029 151 1.100 1007 152 1.082 986 153 1.064 965 154 1.047 945 155 1.029 925 156 1.012 906 157 0.995 887 158 0.978 868 159 0.962 850 160 0.945 832 161 0.929 815 162 0.914 798 163 0.898 782 164 0.883 765 165 0.868 750 166 0.853 734

TEMPERATURE VOLTAGE RESISTANCE

(F) DROP (V) (Ohms)

167 0.838 719 168 0.824 705 169 0.810 690 170 0.797 677 171 0.783 663 172 0.770 650 173 0.758 638 174 0.745 626 175 0.734 614 176 0.722 602 177 0.710 591 178 0.700 581 179 0.689 570 180 0.678 561 181 0.668 551 182 0.659 542 183 0.649 533 184 0.640 524 185 0.632 516 186 0.623 508 187 0.615 501 188 0.607 494 189 0.600 487 190 0.592 480 191 0.585 473 192 0.579 467 193 0.572 461 194 0.566 456 195 0.560 450 196 0.554 445 197 0.548 439 198 0.542 434 199 0.537 429 200 0.531 424 201 0.526 419 202 0.520 415 203 0.515 410 204 0.510 405 205 0.505 401 206 0.499 396 207 0.494 391 208 0.488 386 209 0.483 382 210 0.477 377 211 0.471 372 212 0.465 367 213 0.459 361 214 0.453 356 215 0.446 350 216 0.439 344 217 0.432 338 218 0.425 332 219 0.417 325 220 0.409 318 221 0.401 311 222 0.393 304 223 0.384 297 224 0.375 289 225 0.366 282

Page 95

Table 14B — Thermistor Temperature (C) vs Resistance/Voltage Drop

TEMPERATURE VOLTAGE RESISTANCE

−40 4.896 168 230

−39 4.889 157 440

−38 4.882 147 410

−37 4.874 138 090

−36 4.866 129 410

−35 4.857 121 330

−34 4.848 113 810

−33 4.838 106 880

−32 4.828 100 260

−31 4.817 94 165

−30 4.806 88 480

−29 4.794 83 170

−28 4.782 78 125

−27 4.769 73 580

−26 4.755 69 250

−25 4.740 65 205

−24 4.725 61 420

−23 4.710 57 875

−22 4.693 54 555

−21 4.676 51 450

−20 4.657 48 536

−19 4.639 45 807

−18 4.619 43 247

−17 4.598 40 845

−16 4.577 38 592

−15 4.554 38 476

−14 4.531 34 489

−13 4.507 32 621

−12 4.482 30 866

−11 4.456 29 216

−10 4.428 27 633

−9 4.400 26 202

−8 4.371 24 827

−7 4.341 23 532

−6 4.310 22 313

−5 4.278 21 163

−4 4.245 20 079

−3 4.211 19 058

−2 4.176 18 094

−1 4.140 17 184 0 4.103 16 325 1 4.065 15 515 2 4.026 14 749 3 3.986 14 026 4 3.945 13 342 5 3.903 12 696 6 3.860 12 085 7 3.816 11 506 8 3.771 10 959 9 3.726 10 441

10 3.680 9 949 11 3.633 9 485 12 3.585 9 044 13 3.537 8 627 14 3.487 8 231 15 3.438 7 855 16 3.387 7 499 17 3.337 7 161 18 3.285 6 840 19 3.234 6 536 20 3.181 6 246 21 3.129 5 971 22 3.076 5 710 23 3.023 5 461 24 2.970 5 225 25 2.917 5 000 26 2.864 4 786 27 2.810 4 583 28 2.757 4 389 29 2.704 4 204 30 2.651 4 028 31 2.598 3 861 32 2.545 3 701 33 2.493 3 549 34 2.441 3 404 35 2.389 3 266 36 2.337 3 134 37 2.286 3 008 38 2.236 2 888 39 2.186 2 773 40 2.137 2 663 41 2.087 2 559 42 2.039 2 459 43 1.991 2 363 44 1.944 2 272

TEMPERATURE VOLTAGE RESISTANCE

45 1.898 2 184 46 1.852 2 101 47 1.807 2 021 48 1.763 1 944 49 1.719 1 871 50 1.677 1 801 51 1.635 1 734 52 1.594 1 670 53 1.553 1 609 54 1.513 1 550 55 1.474 1 493 56 1.436 1 439 57 1.399 1 387 58 1.363 1 337 59 1.327 1 290 60 1.291 1 244 61 1.258 1 200 62 1.225 1 158 63 1.192 1 118 64 1.160 1 079 65 1.129 1 041 66 1.099 1 006 67 1.069 971 68 1.040 938 69 1.012 906 70 0.984 876 71 0.949 836 72 0.920 805 73 0.892 775 74 0.865 747 75 0.838 719 76 0.813 693 77 0.789 669 78 0.765 645 79 0.743 623 80 0.722 602 81 0.702 583 82 0.683 564 83 0.665 547 84 0.648 531 85 0.632 516 86 0.617 502 87 0.603 489 88 0.590 477 89 0.577 466 90 0.566 456 91 0.555 446 92 0.545 436 93 0.535 427 94 0.525 419 95 0.515 410 96 0.506 402 97 0.496 393 98 0.486 385

99 0.476 376 100 0.466 367 101 0.454 357 102 0.442 346 103 0.429 335 104 0.416 324 105 0.401 312 106 0.386 299 107 0.370 285

Page 96

Control Modules

Turn the controller power off before servicing the controls. This ensures safety and prevents damage to the controller.

The Processor/Sensor Input/Output module (PSIO), 8-input (Options) modules, Starter Management Module (SMM), 4-in/2-out module, and the Local Interface Device (LID) module perform continuous diagnostic evaluations of the hardware to determine its condition. Proper operation of all modules is indicated by LEDs (light-emitting diodes) located on the side of the LID (Fig. 49); on the top horizontal surface of the PSIO (Fig. 50), SMM, and 8-input modules; and on the 4-in/ 2-out module.

RED LEDs PSIO Module — If the LED is blinking continuously at a

2-second rate, it is indicating proper operation. If it is lit continuously it indicates a problem requiring replacement of the module. Off continuously indicates that the power should be checked. If the red LED blinks 3 times per second, a software error has been discovered and the module must be replaced. If there is no input power, check the fuses and the circuit breaker. If the fuses are good, check for a shorted secondary of transformer, or if power is present to the module, replace the module.

4-In/2-Out Module — If the LED is blinking, this module is operating properly.Asteady red light indicates a module failure. Replace the 4-In/2-Out module.

GREEN LEDs — There are 1 or 2 green LEDs on each type of module. These LEDs indicate communication status between different parts of the controller and the network modules as follows:

LID Module Upper LED — Communication with CCN network, if present;

blinks when communication occurs. Lower LED — Communication with PSIO module; must blink

every 5 to 8 seconds when the LID default screen is displayed.

PSIO Module GreenLED Closest to Communications Connection — Com-

munication with SMM and 8-input module; must blink continuously.

Other Green LED — Communication with LID; must blink every 3 to 5 seconds.

8-Input Modules and SMM — Communication with PSIO module; blinks continuously.

4-In/2-Out Module — Communication with PSIO module; blinks continuously.

NOTE: Address switches on this module can be at any position. Addresses are only changed through the LID screen for CCN.

Fig. 49 — LID Module (Rear View) and

LED Locations

Notes on Module Operation

1. The chiller operator monitors and modiﬁes conﬁgurations in the microprocessor through the 4 softkeys and the LID. Communication with the LID and the PSIO is accomplished through the CCN bus (COMM1). The communication between the PSIO, SMM, both 8-input modules, and the 4-in/2-out module is accomplished through the sensor bus (COMM3), which is a 3-wire cable. On the sensor bus terminal strips, Terminal 1 of the PSIO module is connected to Terminal 1 of each of the other modules. Terminals 2 and 3 are connected in the same manner, except for the connection to the 4-in/2-out module. See Fig. 51.

2. If a green LED is on continuously, check the communication wiring. If a green LED is off, check the red LED operation. If the red LED is normal, check the module address switches (Fig. 52-54). Proper addresses are set as shown below:

MODULE

SMM (Starter Management Module) 32 8-input Options Module 1 64 8-input Options Module 2 72

MODULE

4-In/2-Out Module OOOOCOCO

O—Open C—Closed

12345678

SWITCH

ADDRESS

S1 S2

Fig. 50 — PSIO Module LED Locations

Page 97

If all modules indicate a communications failure, check the communications plug on the PSIO module for proper seating.Also check the wiring (CCN bus — 1:red, 2:wht, 3:blk; Sensor bus — 1:red, 2:blk, 3:clr/wht). If a good connection is assured and the condition persists, replace the PSIO module.

If only one 8-input module, the SMM, or the 4-in/2-out module indicates a communication failure, check the communications plug on that module. If a good connection is assured and the condition persists, replace the module.

All system operating intelligence rests in the PSIO module. Some safety shutdown logic resides in the SMM in case communications are lost between the 2 modules. The PSIO monitors conditions using input ports on the PSIO, the SMM, the 8-input modules, and the 4-in/2-out modules. Outputs are controlled by the PSIO and SMM as well.

3. Power is supplied to the modules within the control panel. The transformers are located within the power panel, with the exception of the SMM, which operates from a 24-vac power source and has its own 24-vac transformer located in the starter.

In the power panel, T1 supplies power 21-vac to the LID, the PSIO, and the 5-vac power supply for the transducers. T3 supplies 24-vac power to the 4-in/2-out module. T4 is another 21-vac transformer, which supplies power to both 8-input modules (if present). T4 is capable of supplying power to two modules; if additional modules are added, another power supply will be required.

Power is connected to Terminals 1 and 2 of the power input connection on each module.

PSIO (J8)

GRD

SMM (J5)

GRD

8-INPUT (J5)

GRD

8-INPUT (J5)

GRD

4-IN/2-OUT (J3)

GRD

NOTE:Address switcheson this module can be at any position.Addresses can only be changed through the LID or CCN.

Fig. 52 — Processor (PSIO) Module

Starter Management Module (SMM) (Fig. 53)

INPUTS — Inputs on strips J2 and J3 are a mix of analog and discrete (on/off) inputs. The chiller application determines which terminals are used. Always refer to the individual unit wiring diagram for terminal numbers.

OUTPUTS — Outputs are 24 vdc and wired to strip J1. There are 2 terminals used per output.

LEGEND

GRD — Ground J—Junction SMM — Starter Management

Module

PSIO — Processor/Sensor Input/

Output Module Pins

Fig. 51 — Sensor Input/Output (SIO) Wiring

Schematic for COMM3 Bus

Processor/Sensor Input/Output Module (PSIO) (Fig. 52)

INPUTS — Each input channel has 3 terminals; only 2 of the terminals are used. The chiller application determines which terminals are normally used. Always refer to individual unit wiring diagrams for terminal numbers.

OUTPUTS — Output is 20 vdc. There are 3 terminals per output, only 2 of which are used, depending on the application. Refer to the unit wiring diagram.

NOTE: SMM address switches should be set as follows: S1 set at 3; S2 set at 2.

Fig. 53 — Starter Management Module (SMM)

Page 98

Options Modules (8-Input) — The options modules

are optional additions to the PIC, and are used to add temperature reset inputs, spare sensor inputs, and demand limit inputs. Each option module contains 8 inputs, each input meant for a speciﬁc duty. See the wiring diagram for exact module wire terminations. Inputs for each of the options modules available include the following:

4 to 20 mA Auto. Demand Reset 4 to 20 mA Auto. Chilled Water Reset Common Chilled Water Supply Temperature Common Chilled Water Return Temperature Remote Temperature Reset Sensor Spare Temperature 1 Spare Temperature 2 Spare Temperature 3

Terminal block connections are provided on the options modules. All sensor inputs are ﬁeld wired and installed. Options module 1 can be factory or ﬁeld-installed. Options module 2 is shipped separately and must be ﬁeld installed. For installation, refer to the unit or ﬁeld wiring diagrams. Be sure to address the module for the proper module number (Fig. 54) and to conﬁgure the chiller for each feature being used.

OPTIONS MODULE 1

OPTIONS MODULE 2 4 to 20 mA Spare 1

4 to 20 mA Spare 2 Spare Temperature 4 Spare Temperature 5 Spare Temperature 6 Spare Temperature 7 Spare Temperature 8 Spare Temperature 9

conﬁgurations. The inputs monitor the gear oil temperature and pressure. InputAI#2 should be factory-set with the jumper on (T). Inputs AI#3, and AI#4 should be factory set on (V).

OUTPUTS — The two analog outputs are each conﬁgurable by on-board jumpers as 0 to 10 vdc (maximum current: 10 mA) or 4 to 20 mA (maximum load: 600 ohms) outputs. The outputs control the relay that activates the gear oil pump starter. Outputs AO#1 and AO#2 should be factory set with the jumper on (V).

This module has a ﬁeld-conﬁgurable DIP (dual in-line package) switch to designate its address. It should be factory set with the following switches open: 1, 2, 3, 4, 6, and 8. Switches 5 and 7 should be closed.

Note the SIO bus wiring for this module. Unlike the standard PIC modules, Pin 2 is negative and Pin 3 is the ground (or common). See Fig. 51.

Replacing Defective Processor Modules — The

replacement part number is printed on a small label on the front of the PSIO module. The model and serial numbers are printed on the unit nameplate located on an exterior corner post. The proper software is factory-installed by Carrier in the replacement module. When ordering a replacement processor module (PSIO), specify complete replacement part number, full unit model number, and serial number. This new unit requires reconﬁguration to the original chiller data by the installer. Follow the procedures described in the Set Up Chiller Control Conﬁguration section on page 54. Electrical shock can cause personal injury.Disconnect all electrical power before servicing.

SWITCH SETTING OPTIONS MODULE 1 OPTIONS MODULE 2

S1 67 S2 42

Fig. 54 — Options Module

Four-In/Two-Out Module (Fig. 55)

INPUTS — The four analog inputs each have 3 terminals and are conﬁgurable by movable on-board jumpers as thermistor (T), 4 to 20 mA (C), or 0 to 10 vdc (V)

Electrical shock can cause personal injury. Disconnect all electrical power before servicing.

INSTALLATION OF NEW PSIO MODULE

1. Verify that the existing PSIO module is defective by using the procedure described in the Notes on Module Operation section, page 96, and the Control Modules section, page 96. Do not access theATTACHTO NETWORK DEVICE screen if the LID displays a communication failure.

2. Data regarding the PSIO conﬁguration should have been recorded and saved. This data must be reconﬁgured into the LID. If this data is not available, follow the procedures described in the Set Up Chiller Control Conﬁguration section, page 54. Record the TOTAL COMPRES- SOR STARTSand the COMPRESSOR ONTIME from the STATUS01 table on the LID.

If a CCN Building Supervisor or Service Tool is present, the module conﬁguration should have already been uploaded into memory; then, when the new module is installed, the conﬁguration can be downloaded from the computer (if the software version is the same).

Any communication wires from other chillers or CCN modules must be disconnected.

3. Check that all power to the unit is off. Carefully disconnect all wires from the defective module by unplugging the 6 connectors. It is not necessary to remove any of the individual wires from the connectors.

4. Remove the defective PSIO by removing its mounting screw with a long-shaft Phillips screwdriver and removing the module from the control box. Save the screw for later use. The green ground wire is held in place with the module mounting screw.

5. Package the defective module in the carton of the new module for return to Carrier.

Page 99

6. Restore control system power (the LID displays, COMMUNICATION FAILURE at the bottom of the screen).

7. Access the SERVICE menu. Highlight and select the ATTACH TO NETWORK DEVICE screen. Press

the ATTACH softkey. (The LID displays, UPLOADING TABLES. PLEASE WAIT; then, COMMUNICA-

TION FAILURE.) Press the EXIT

8. Turn off control power.

9. Mount the new module in the unit control box using a long-shaft Phillips screwdriver and the screw saved in Step 4 on page 98. Make sure that the green grounding wire is reinstalled along with the mounting screw.

10. Connect the LID communication wires (CCN bus) and the power wires. If CCN wiring has been attached to the CCN bus, disconnect the wires. Attach the sensor bus plug and the input and output plugs.

11. Carefully check all wiring connections before restoring

power.

12. Restore control power and verify that the red and green LEDs on the PSIO are functioning properly.

13. The LID should indicate AVAILABLE MEMORY and a value. This value should start to decrease. (If it does not, check the LID wiring to the PSIO; ensure connection to the proper plug.) The bottom of the screen displays, UPLOADING TABLES, PLEASE WAIT.

14. After the PSIO tables have been uploaded into the LID, access the STATUS01 screen. Move the highlight bar to the TOTAL COMPRESSOR STARTS line. Press the

SELECT DECREASE

softkey and then, using the INCREASE or

softkeys, change the value until it is the

softkey.

same as the value from the old module. Press the

ENTER

15. Move the highlight bar to the COMPRESSOR ONTIME line. Press the SELECT ing the INCREASE

this value until it matches the old module run hours. Press the SELECT

16. Change the address of the PSIO In the CONTROLLER IDENTIFICATION table back to its previous value. Write the address on the PSIO.

17. Use the conﬁguration sheets (pages CL-3 to CL-11) to input set point, conﬁguration, and schedule information into the PSIO. The TIME AND DATE table from the SERVICE menu must also be set. A Building Supervisor terminal can be used to download the old conﬁguration into the PSIO.

18. Access the CONTROL TEST table and perform the control tests to verify all that all tested functions are working properly.

If the software version has been updated, a CCN download of the conﬁguration will not be allowed. Conﬁgure the PSIO by hand, and upload the PSIO into the network using the ATTACH TO NETWORK DEVICE screen.

19. Restore the chiller to normal operation; calibrate the motor amps.

softkey to save this value.

softkey and the, us-

or DECREASE softkeys, change

softkey to save this value.

PHYSICAL DATA AND WIRING

SCHEMATICS

Tables 15-26 and Fig. 56-61 provide additional information regarding compressor ﬁts and clearances, physical and electrical data, and wiring schematics for operator convenience during troubleshooting.

Fig. 55 — 4-In/2-Out Module

Page 100

Fig. 56 — Model Number Nomenclature for Compressor Size (See Fig. 1 Also)

Table 15 — 17EX Heat Exchanger Economizer/Storage Vessel, Piping, and Pumpout Unit Weights*

COOLER

SIZE†

45 25,032 11 355 30,098 13 652 2,060 934 3,006 361 1 364 1366 46 25,529 11 580 30,881 14 008 2,160 980 3,192 383 1 448 1450 47 26,025 11 805 31,663 14 362 2,260 1 025 3,378 405 1 532 1533 48 28,153 12 770 34,866 15 815 2,540 1 152 4,173 500 1 893 1893

lb kg lb kg lb kg lb gal kg L

TOTAL

WEIGHT

Dry** Operating†† Refrigerant Water

COOLER CHARGE

ECONOMIZER/

STORAGE

VESSEL

lb kg lb kg lb kg lb kg

7,900 3 583 840 318 1,149 521 210 95

ECONOMIZER

REFRIGERANT

MISCELLANEOUS

PIPING

PUMPOUT

UNIT

CONDENSER

SIZE†

45 16,676 7 564 20,596 9 342 1,200 544 2,720 1 234 46 17,172 7 789 21,280 9 653 1,200 544 2,908 1 319 47 17,669 8 015 21,965 9 963 1,200 544 3,096 1 404 55 20,725 9 401 25,598 11611 1,420 644 3,453 1 566 56 21,663 9 826 26,891 12 198 1,420 644 3,808 1 727 57 22,446 10 182 27,971 12 688 1,420 644 4,105 1 862

*If a chiller conﬁguration otherthan 2-pass, 150 psig (1034 kPa), NIH waterbox

conﬁguration is used, referto Tables16 and 17to obtainthe additional dryand water weights that must be added to the values shown in this table.

†Cooler and condenser weights shown are based on 2-pass, nozzle-in-head

(NIH) waterboxes with 150 psig (1034 kPa) covers. Includes components attached to cooler, but does not include suction/discharge, elbow, or other interconnecting piping.

CONDENSER TOTAL WEIGHT CONDENSER CHARGE

Dry** Operating†† Refrigerant Water

lb kg lb kg lb kg lb kg

**Dryweight includesall components attached to economizer:covers, ﬂoatvalves,

brackets, control center (31 lb [14 kg]), and power panel (20 lb [9 kg]). Dry weight does not include compressor weight, motor weight, or pumpout condensing unit weight. The pumpout condensing unit weight is 210 lb (95 kg). For compressor and motor weights, refer to Tables 18 and 20A and 20B.

††Operating weight includes dry weight, refrigerant weight, and water weight.

Table 16 — Additional Cooler Weights*

COOLER

FRAME

WATERBOX

TYPE

NUMBER

OF PASSES

DESIGN MAXIMUM

WATER PRESSURE

psig kPa lb kg lb gal kg L

NIH 1, 3 150 1034 515 234 — — — — NIH 1, 3 300 2068 2941 1334 — — — — NIH 2 300 2068 2085 946 — — — —

Marine 1, 3 150 1034 2100 953 5102 612 2314 2314 Marine 2 150 1034 792 359 2551 306 1157 1157 Marine 1, 3 300 2068 3844 1744 5102 612 2314 2314 Marine 2 300 2068 2536 1150 2551 306 1157 1157

*When using a chiller conﬁguration other than 2-pass, NIH waterboxes with 150 psig (1038 kPa) covers, add the weighs listed in this table to the

appropriate weights in Table 15 to obtain the correct cooler weight.

ADDITIONAL

DRY WEIGHT

ADDITIONAL

WATER WEIGHT

100

Carrier 17EX User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual